Lightweight compositions and articles containing such

ABSTRACT

A lightweight cementitious composition containing from 22 to 90 volume percent of a cement composition and from 10 to 78 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, where after the lightweight cementitious composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39. The cementitious composition can be used to make concrete masonry units, construction panels, road beds and other articles and can be included as a layer on wall panels and floor panels and can be used in insulated concrete forms. Aspects of the lightweight cementitious composition can be used to make lightweight structural units.

REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority of U.S. ProvisionalApplication Ser. Nos. 60/656,596 filed Feb. 25, 2005 and 60/664,120filed Mar. 22, 2005, both entitled “Composite Pre-Formed BuildingPanels,” 60/664,230 filed Mar. 22, 2005 entitled “Light Weight ConcreteComposite Using EPS Beads,” 60/686,858 filed Jun. 2, 2005 entitled“Lightweight Compositions and Materials” and U.S. ProvisionalApplication Ser. No. 60/728,839 filed Oct. 21, 2005 entitled “CompositePre-Formed Insulated Concrete Forms,” which are all herein incorporatedby reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to novel compositions, materials,methods of their use and methods of their manufacture that are generallyuseful as agents in the construction and building trades. Morespecifically, the compounds of the present invention can be used inconstruction and building applications that benefit from a relativelylightweight, extendable, moldable, pourable, material that has highstrength and often improved insulation properties.

2. Description of the Prior Art

In the field of preparation and use of lightweight cementitiousmaterials, such as so-called lightweight concrete, the materials thathave been available to the trades up until now have generally requiredthe addition of various constituents to achieve a strong but lightweightconcrete mass that has a high homogeneity of constituents and which isuniformly bonded throughout the mass.

U.S. Pat. Nos. 3,214,393, 3,257,338 and 3,272,765 disclose concretemixtures that contain cement, a primary aggregate, particulate expandedstyrene polymer, and a homogenizing and/or a surface-active additive.

U.S. Pat. No. 3,021,291 discloses a method of making cellular concreteby incorporating into the concrete mixture, prior to casting themixture, a polymeric material that will expand under the influence ofheat during curing. The shape and size of the polymeric particles is notcritical.

U.S. Pat. No. 5,580,378 discloses a lightweight cementitious productmade up of an aqueous cementitious mixture that can include fly ash,Portland cement, sand, lime and, as a weight saving component,micronized polystyrene particles having particle sizes in the range of50 to 2000 μm and a density of about 1 lb/ft³. The mixture can be pouredinto molded products such as foundation walls, roof tiles, bricks andthe like. The product can also be used as a mason's mortar, a plaster, astucco or a texture.

JP 9 071 449 discloses a lightweight concrete that includes Portlandcement and a lightweight aggregate such as foamed polystyrene, perliteor

vermiculite as a part or all parts of the aggregate. The foamedpolystyrene has a granule diameter of 0.1-10 mm and a specific gravityof 0.01-0.08.

U.S. Pat. Nos. 5,580,378, 5,622,556, and 5,725,652 disclose lightweightcementitious products made up of an aqueous cementitious mixture thatincludes cement and expanded shale, clay, slate, fly ash, and/or lime,and a weight saving component, which is micronized polystyrene particleshaving particle sizes in the range of 50 to 2000 μm, and characterizedby having water contents in the range of from about 0.5% to 50% v/v.

U.S. Pat. No. 4,265,964 discloses lightweight compositions forstructural units such as wallboard panels and the like, which containlow density expandable thermoplastic granules; a cementitious basematerial, such as, gypsum; a surfactant; an additive which acts as afrothing agent to incorporate an appropriate amount of air into themixture; a film forming component; and a starch. The expandablethermoplastic granules are expanded as fully as possible.

WO 98 02 397 discloses lightweight-concrete roofing tiles made bymolding a hydraulic binder composition containing synthetic resin foamsas the aggregate and having a specific gravity of about 1.6 to 2.

WO 00/61519 discloses a lightweight concrete that includes a blend offrom around 40% to 99% of organic polymeric material and from 1% toaround 60% of an air entraining agent. The blend is used for preparinglightweight concrete that uses polystyrene aggregate. The blend isrequired to disperse the polystyrene aggregate and to improve the bondbetween the polystyrene aggregate and surrounding cementitious binder.

WO 01/66485 discloses a lightweight cementitious mixture containing byvolume: 5 to 80% cement, 10 to 65% expanded polystyrene particles; 10 to90% expanded mineral particles; and water sufficient to make a pastewith a substantially even distribution of expanded polystyrene afterproper mixing.

U.S. Pat. No. 6,851,235 discloses a building block that includes amixture of water, cement, and expanded polystyrene (EPS) foam beads thathave a diameter from 3.18 mm (⅛ inch) to 9.53 mm (⅜ inch) in theproportions of from 68 to 95 liters (18 to 25 gallons) water; from 150to 190 kg (325 to 425 lb) cement; and from 850 to 1400 liters (30 to 50cubic feet) Prepuff beads.

Generally, the prior art recognizes the utility of using expandedpolymers, in some form, in concrete compositions, to reduce the overallweight of the compositions. The expanded polymers are primarily added totake up space and create voids in the concrete and the amount of “airspace” in the expanded polymer is typically maximized to achieve thisobjective. Generally, the prior art assumes that expanded polymerparticles will lower the strength and/or structural integrity oflightweight concrete compositions. Further, concrete articles made fromprior art lightweight concrete compositions have at best inconsistentphysical properties, such as Young's modulus, thermal conductivity, andcompressive strength, and typically demonstrate less than desirablephysical properties.

Concrete walls in building construction are most often produced by firstsetting up two parallel form walls and pouring concrete into the spacebetween the forms. After the concrete hardens, the builder then removesthe forms, leaving the cured concrete wall.

This prior art technique has drawbacks. Formation of the concrete wallsis inefficient because of the time required to erect the forms, waituntil the concrete cures, and take down the forms. This prior arttechnique, therefore, is an expensive, labor-intensive process.

Accordingly, techniques have developed for forming modular concretewalls, which use a foam insulating material. The modular form walls areset up parallel to each other and connecting components hold the twoform walls in place relative to each other while concrete is pouredthere between. The form walls, however, remain in place after theconcrete cures. That is, the form walls, which are constructed of foaminsulating material, are a permanent part of the building after theconcrete cures. The concrete walls made using this technique can bestacked on top of each other many stories high to form all of abuilding's walls. In addition to the efficiency gained by retaining theform walls as part of the permanent structure, the materials of the formwalls often provide adequate insulation for the building.

Although the prior art includes many proposed variations to achieveimprovements with this technique, drawbacks still exist for each design.The connecting components used in the prior art to hold the walls areconstructed of (1) plastic foam, (2) high density plastic, or (3) ametal bridge, which is a non-structural support, i.e., once the concretecures, the connecting components serve no function. Even so, thesemembers provide thermal and sound insulation functions and have longbeen accepted by the building industry.

Thus, current insulated concrete form technology requires the use ofsmall molded foam blocks normally 12 to 24 inches in height with astandard length of four feet. The large amount of horizontal andvertical joints that require bracing to correctly position the blocksduring a concrete pour, restricts their use to shorter wall lengths andlower wall heights. Wall penetrations such as windows and doors requireskillfully prepared and engineered forming to withstand the pressuresexerted upon them during concrete placement. Plaster finishing crewshave difficulty hanging drywall on such systems due to the problem oflocating molded in furring strips. The metal or plastic furring stripsin current designs are non-continuous in nature and are normallyembedded within the foam faces. The characteristics present in currentblock forming systems require skilled labor, long lay-out times,engineered blocking and shoring and non-traditional finishing skills.This results in a more expensive wall that is not suitable for largerwall construction applications. The highly skilled labor force that isrequired to place, block, shore and apply finishes in a block systemseriously restricts the use of such systems when compared to traditionalconcrete construction techniques.

One approach to solving the problem of straight and true walls on largerlayouts has been to design larger blocks. Current existing manufacturingtechnology has limited this increase to 24 inches in height and eightfeet in length. Other systems create hot wire cut opposing foamedplastic panels mechanically linked together in a secondary operationutilizing metal or plastic connectors. These panels are normally 48inches in width and 8 feet in height and do not contain continuousfurring strips.

However, none of the approaches described above adequately address theproblems of form blowout at higher wall heights due to pressure exertedby the poured concrete, fast and easy construction with an unskilledlabor force, and ease of finishing the walls with readily ascertainableattachment points.

Therefore, there is a need in the art for lightweight concretecompositions that provide lightweight concrete articles havingpredictable and desirable physical properties as well as for compositepre-formed building panels and insulated concrete forms with internalblocking and bracing elements that overcome the above-describedproblems.

SUMMARY OF THE INVENTION

The present invention provides a lightweight cementitious compositioncontaining from 22 to 90 volume percent of a cement composition and from10 to 78 volume percent of particles having an average particle diameterof from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc,an aspect ratio of from 1 to 3, wherein after the lightweightcementitious composition is set, it has a compressive strength of atleast 1700 psi as tested according to ASTM C39.

The present invention also provides the above-described lightweightcementitious composition set in the form of concrete masonry units(CMUs), construction articles, pre-cast/pre-stressed constructionarticles, construction panels, or road beds.

The present invention further provides a method of making an optimizedlightweight concrete article that includes:

-   -   identifying the desired density and strength properties of a set        lightweight concrete composition;    -   determining the type, size and density of polymer beads to be        used in the lightweight concrete composition;    -   determining the size and density the polymer beads are to be        expanded to;    -   optionally expanding the polymer beads to form expanded polymer        beads;    -   dispersing the polymer beads in a cementitious mixture to form        the lightweight concrete composition; and    -   allowing the lightweight concrete composition to set in a        desired form.

The present invention additionally provides a composite building panelthat includes:

-   -   a central body, substantially parallelepipedic in shape,        comprised of an expanded polymer matrix, having opposite faces,        a top surface, and an opposing bottom surface;    -   at least one embedded framing studs longitudinally extending        across the central body between said opposite faces, having a        first end embedded in the expanded polymer matrix, a second end        extending away from the bottom surface of the central body, and        one or more expansion holes located in the embedded stud between        the first end of the embedded stud and the bottom surface of the        central body, wherein, the central body comprises a polymer        matrix that expands through the expansion holes; and    -   a concrete layer containing the above-described lightweight        cementitious composition covering at least a portion of the top        surface and/or bottom surface.

The present invention also provides a composite floor panel thatincludes:

-   -   a central body, substantially parallelepipedic in shape,        containing an expanded polymer matrix, having opposite faces, a        top surface, and an opposing bottom surface; and    -   two or more embedded floor joists longitudinally extending        across the central body between said opposite faces, having a        first end embedded in the expanded polymer matrix having a first        transverse member extending from the first end generally        contacting or extending above the top surface, a second end        extending away from the bottom surface of the central body        having a second transverse member extending from the second end,        and one or more expansion holes located in the embedded joists        between the first end of the embedded joists and the bottom        surface of the central body;    -   wherein, the central body includes a polymer matrix that expands        through the expansion holes;    -   wherein the embedded joists include one or more utility holes        located in the embedded joists between the bottom surface of the        central body and the second end of the embedded joists and the        space defined by the bottom surface of the central body and the        second ends of the embedded joists is adapted for accomodating        utility lines;    -   wherein a concrete layer containing the above-described        lightweight cementitious composition covers at least a portion        of the top surface and/or bottom surface; and    -   wherein the composite floor panel is positioned generally        perpendicular to a structural wall and/or foundation.

The present invention further provides an insulated concrete structurethat includes:

-   -   a first body, substantially parallelepipedic in shape,        containing an expanded polymer matrix, having opposite faces, a        first surface, and an opposing second surface;    -   a second body, substantially parallelepipedic in shape,        containing an expanded polymer matrix, having opposite faces, a        first surface, an opposing second surface; and    -   one or more reinforcing embedded studs logitudinally extending        across the first body and the second body between the first        surfaces of each body, having a first end embedded in the        expanded polymer matrix of the first body, and a second end        embedded in the expanded polymer matrix of the second body, one        or more expansion holes located in the portion of the embedded        studs embedded in the first body and the second body;    -   wherein, the first body and the second body include a polymer        matrix that expands through the expansion holes; and the space        defined between the first surfaces of the first body and the        second body is capable of accepting concrete poured therein; and    -   wherein a concrete layer containing the above-described        lightweight cementitious composition fills at least a portion of        a space between the first surface of the first body and the        first surface of the second body.

The present invention additionally provides a lightweight structuralunit that includes:

-   -   a core, having a first major face and a second major face, the        core containing a solid set lightweight cementitious composition        that includes 22 to 90 volume percent of a cement composition        and from 10 to 78 volume percent of particles having an average        particle diameter of from 0.2 mm to 8 mm, a bulk density of from        0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3    -   a first face covering applied over at least a portion of the        first major face; and    -   a second face covering applied over at least a portion of the        second major face.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top plan view of a pre-formed insulated concrete formaccording to the invention;

FIG. 2 shows a top plan view of a pre-formed insulated concrete formaccording to the invention;

FIG. 3 shows a cross-sectional view of a pre-formed insulated concreteform according to the invention;

FIG. 4 shows a partial perspective view of a stud used in the invention;

FIG. 5 shows a perspective view of a pre-formed insulated concrete formaccording to the invention;

FIG. 6 shows a perspective view of the concrete and stud portion of aninsulated concrete form according to the invention;

FIG. 7 shows a perspective view of the concrete and a stud portion of aninsulated concrete form according to the invention;

FIG. 8 shows a partial perspective view of a stud used in the invention;

FIG. 9 shows a plan view of an insulated concrete form system accordingto the invention;

FIG. 10 shows an insulated concrete form corner unit according to theinvention;

FIG. 11 shows a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to the invention;

FIG. 12 shows a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to the invention;

FIG. 13 shows a cross-sectional view of a reinforced body for use inmaking the concrete composite pre-formed tilt-up insulated panel inFIGS. 11 and 12;

FIG. 14 shows a perspective view of an embedded metal stud for use inmaking the reinforced body in FIG. 13 and the concrete compositepre-formed tilt-up insulated panels in FIGS. 11 and 12;

FIG. 15 shows a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to the invention;

FIG. 16 shows a cross-sectional view of a reinforced body for use inmaking the concrete composite pre-formed tilt-up insulated panel in FIG.15;

FIG. 17 shows a cross-sectional view of a concrete composite pre-formedtilt-up insulated panel according to the invention; and

FIG. 18 shows a perspective view of an embedded metal stud for use inmaking the reinforced body in FIG. 16 and the concrete compositepre-formed tilt-up insulated panels in FIGS. 13 and 15;

FIG. 19 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 20 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 21 shows a cross-sectional view of a pre-formed building panelaccording to the invention;

FIG. 22 shows a cross-sectional view of a concrete composite pre-formedbuilding panel system according to the invention;

FIG. 23 shows a perspective view of a floor system according to theinvention;

FIG. 24 shows a perspective view of a floor system according to theinvention;

FIG. 25 shows a perspective view of a construction method according tothe invention;

FIG. 26 shows a partial perspective view of a level track according tothe invention;

FIG. 27 is a scanning electron micrograph of the surface of a prepuffbead used in the invention;

FIG. 28 is a scanning electron micrograph of the interior of a prepuffbead used in the invention;

FIG. 29 is a scanning electron micrograph of the surface of a prepuffbead used in the invention;

FIG. 30 is a scanning electron micrograph of the interior of a prepuffbead used in the invention;

FIG. 31 is a scanning electron micrograph of the surface of a prepuffbead used in the invention; and

FIG. 32 is a scanning electron micrograph of the interior of a prepuffbead used in the invention.

DETAILED DESCRIPTION OF THE INVENTION

Other than in the operating examples or where otherwise indicated, allnumbers or expressions referring to quantities of ingredients, reactionconditions, etc. used in the specification and claims are to beunderstood as modified in all instances by the term “about.”Accordingly, unless indicated to the contrary, the numerical parametersset forth in the following specification and attached claims areapproximations that can vary depending upon the desired properties,which the present invention desires to obtain. At the very least, andnot as an attempt to limit the application of the doctrine ofequivalents to the scope of the claims, each numerical parameter shouldat least be construed in light of the number of reported significantdigits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical values, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between andincluding the recited minimum value of 1 and the recited maximum valueof 10; that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10. Because the disclosednumerical ranges are continuous, they include every value between theminimum and maximum values. Unless expressly indicated otherwise, thevarious numerical ranges specified in this application areapproximations.

As used herein the term “formable material” refers to any material inliquid, semi-solid, viscoelastic, and/or other suitable form that can bemanipulated and placed into an enclosed space of predetermined shapeand/or dimensions where it becomes solid by either cooling, curing,and/or setting.

As used herein, the term “particles containing void spaces” refer toexpanded polymer particles, prepuff particles, and other particles thatinclude cellular and/or honeycomb-type chambers at least some of whichare completely enclosed, that contain air or a specific gas orcombination of gasses, as a non-limiting example prepuff particles asdescribed herein.

As used herein the terms “cement” and “cementitious” refer to materialsthat bond a concrete or other monolithic product, not the final productitself. In particular, hydraulic cement refers to a material that setsand hardens by undergoing a hydration reaction in the presence of asufficient quantity of water to produce a final hardened product.

As used herein, the term “cementitious mixture” refers to a compositionthat includes a cement material, and one or more fillers, adjuvants, orother materials known in the art that form a slurry that hardens uponcuring. Cement materials include, but are not limited to, hydrauliccement, gypsum, gypsum compositions, lime and the like and may or maynot include water. Adjuvants and fillers include, but are not limited tosand, clay, fly ash, aggregate, air entrainment agents, colorants, waterreducers/superplasticizers, and the like.

As used herein, the term “concrete” refers to a hard strong buildingmaterial made by mixing a cementitious mixture with sufficient water tocause the cementitious mixture to set and bind the entire mass.

As used herein, the terms “(meth)acrylic” and “(meth)acrylate” are meantto include both acrylic and methacrylic acid derivatives, such as thecorresponding alkyl esters often referred to as acrylates and(meth)acrylates, which the term “(meth)acrylate” is meant to encompass.

As used herein, the term “polymer” is meant to encompass, withoutlimitation, homopolymers, copolymers, graft copolymers, and blends andcombinations thereof.

In its broadest context, the present invention provides a method ofcontrolling air entrainment in a formed article. The formed article canbe made from any formable material, where particles containing voidspaces are used to entrain air in a structurally supportive manner. Anysuitable formable material can be used, so long as the particlescontaining void spaces are not damaged during the forming process. Assuch, when suitable particles are used, the formable material can be acementitious composition, a metal, a ceramic, a plastic, a rubber, or acomposite material.

Metals that can be used in the invention include, but are not limited toaluminum, iron, titanium, molybdenum, nickel, copper, combinationsthereof and alloys thereof. Suitable ceramics include inorganicmaterials such as pottery, enamels and refractories and include but arenot limited to metal silicates, metal oxides, metal nitrides andcombinations thereof. Suitable plastics include, but are not limited topolyolefins, homopolymers of vinyl aromatic monomers; copolymers ofvinyl aromatic monomers, poly(meth)acrylates, polycarbonates,polyesters, polyamides, and combinations thereof. Suitable rubbersinclude natural rubbers, synthetic rubbers and combinations thereof.

As used herein, the term “composite material” refers to a solid materialwhich includes two or more substances having different physicalcharacteristics and in which each substance retains its identity whilecontributing desirable properties to the whole. As a non-limitingexample, composite materials can include a structural material made ofplastic within which a fibrous material, such as silicon carbide, glassfibers, aramid fibers, and the like, are embedded.

The particles are selected such that they do not melt or otherwisebecome damaged during the forming process. For example, a polymerparticle would typically not be used in a metal forming operation.Suitable materials from which the particles containing voids can beselected include polymers, plastics, ceramics, and the like. Whenpolymers and/or plastics are used, they can be expanded materials asdescribed below. When ceramics are used, they are formed with voidstherein. As a non-limiting example, a ceramic can be formed byincorporating a polymer therein, which is subsequently burned awayleaving void spaces in the ceramic. The ceramic with void spaces canthen be used in metal to provide a lightweight formed metal part.

Thus, the present invention is directed to methods of controlling airentrainment where an article is formed by combining a formable materialand particles containing void spaces to provide a mixture and placingthe mixture in a form.

Although the application discloses in detail cementitious mixtures withpolymer particles, the concepts and embodiments described herein can beapplied by those skilled in the art to the other applications describedabove.

Embodiments of the present invention are directed to a lightweightconcrete (LWC) composition that includes a cementitious mixture andpolymer particles. Surprisingly, it has been found that the size,composition, structure, and physical properties of the expanded polymerparticles, and in some instances their resin bead precursors, cangreatly affect the physical properties of LWC articles made from the LWCcompositions of the invention. Of particular note is the relationshipbetween bead size and expanded polymer particle density on the physicalproperties of the resulting LWC articles.

In an embodiment of the invention, the cementitious mixture can be anaqueous cementitious mixture.

The polymer particles, which can optionally be expanded polymerparticles, are present in the LWC composition at a level of at least 10,in some instances at least 15, in other instances at least 20, inparticular situations up to 25, in some cases at least 30, and in othercases at least 35 volume percent and up to 78, in some instances up to75, in other instance up to 65, in particular instances up to 60, insome cases up to 50, and in other cases up to 40 volume percent based onthe total volume of the LWC composition. The amount of polymer will varydepending on the particular physical properties desired in a finishedLWC article. The amount of polymer particles in the LWC composition canbe any value or can range between any of the values recited above.

The polymer particles can include any particles derived from anysuitable expandable thermoplastic material. The actual polymer particlesare selected based on the particular physical properties desired in afinished LWC article. As a non-limiting example, the polymer particles,which can optionally be expanded polymer particles, can include one ormore polymers selected from homopolymers of vinyl aromatic monomers;copolymers of at least one vinyl aromatic monomer with one or more ofdivinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates,acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates;polyesters; polyamides; natural rubbers; synthetic rubbers; andcombinations thereof.

In an embodiment of the invention, the polymer particles includethermoplastic homopolymers or copolymers selected from homopolymersderived from vinyl aromatic monomers including styrene,isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes,chlorostyrene, tert-butylstyrene, and the like, as well as copolymersprepared by the copolymerization of at least one vinyl aromatic monomeras described above with one or more other monomers, non-limitingexamples being divinylbenzene, conjugated dienes (non-limiting examplesbeing butadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates,alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinylaromatic monomer is present in at least 50% by weight of the copolymer.In an embodiment of the invention, styrenic polymers are used,particularly polystyrene. However, other suitable polymers can be used,such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates,polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the polymer particles areexpandable polystyrene (EPS) particles. These particles can be in theform of beads, granules, or other particles convenient for the expansionand molding operations.

In the present invention, particles polymerized in a suspension process,which are essentially spherical resin beads, are useful as polymerparticles or for making expanded polymer particles. However, polymersderived from solution and bulk polymerization techniques that areextruded and cut into particle sized resin bead sections can also beused.

In an embodiment of the invention, resin beads (unexpanded) containingany of polymers or polymer compositions described herein have a particlesize of at least 0.2, in some situations at least 0.33, in some cases atleast 0.35, in other cases at least 0.4, in some instances at least 0.45and in other instances at least 0.5 mm. Also, the resin beads can have aparticle size of up to 3, in some instances up to 2, in other instancesup to 2.5, in some cases up to 2.25, in other cases up to 2, in somesituations up to 1.5 and in other situations up to 1 mm. In thisembodiment, the physical properties of LWC articles made according tothe invention have inconsistent or undesirable physical properties whenresin beads having particle sizes outside of the above described rangesare used to make the expanded polymer particles. The resin beads used inthis embodiment can be any value or can range between any of the valuesrecited above.

The expandable thermoplastic particles or resin beads can optionally beimpregnated using any conventional method with a suitable blowing agent.As a non-limiting example, the impregnation can be achieved by addingthe blowing agent to the aqueous suspension during the polymerization ofthe polymer, or alternatively by re-suspending the polymer particles inan aqueous medium and then incorporating the blowing agent as taught inU.S. Pat. No. 2,983,692. Any gaseous material or material which willproduce gases on heating can be used as the blowing agent. Conventionalblowing agents include aliphatic hydrocarbons containing 4 to 6 carbonatoms in the molecule, such as butanes, pentanes, hexanes, and thehalogenated hydrocarbons, e.g. CFC's and HCFC'S, which boil at atemperature below the softening point of the polymer chosen. Mixtures ofthese aliphatic hydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbonsblowing agents or water can be used as the sole blowing agent as taughtin U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents,water-retaining agents are used. The weight percentage of water for useas the blowing agent can range from 1 to 20%. The texts of U.S. Pat.Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein byreference.

The impregnated polymer particles or resin beads are optionally expandedto a bulk density of at least 0.5 lb/ft³ (0.008 g/cc), in some cases atleast 1.25 lb/ft³ (0.02 g/cc), in other cases at least 1.5 lb/ft³ (0.024g/cc), in some situations at least 1.75 lb/ft³ (0.028 g/cc), in somecircumstances at least 2 lb/ft³ (0.032 g/cc) in other circumstances atleast 3 lb/ft³ (0.048 g/cc) and in particular circumstances at least3.25 lb/ft³ (0.052 g/cc) or 3.5 lb/ft³ (0.056 g/cc). When non-expandedresin beads are used higher bulk density beads can be used. As such, thebulk density can be as high as 40 lb/ft³ (0.64 g/cc). The bulk densityof the polymer particles can be any value or range between any of thevalues recited above.

The expansion step is conventionally carried out by heating theimpregnated beads via any conventional heating medium, such as steam,hot air, hot water, or radiant heat. One generally accepted method foraccomplishing the pre-expansion of impregnated thermoplastic particlesis taught in U.S. Pat. No. 3,023,175.

The impregnated polymer particles can be foamed cellular polymerparticles as taught in U.S. patent application Ser. No. 10/021,716, theteachings of which are incorporated herein by reference. The foamedcellular particles can be polystyrene that are expanded and contain avolatile blowing agent at a level of less than 14 wt %, in somesituations less than 6 wt %, in some cases ranging from about 2 wt % toabout 5 wt %, and in other cases ranging from about 2.5 wt % to about3.5 wt % based on the weight of the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromaticmonomers that can be included in the expanded thermoplastic resin orpolymer particles according to the invention is disclosed in U.S. Pat.Nos. 4,303,756 and 4,303,757 and U.S. Application Publication2004/0152795, the relevant portions of which are herein incorporated byreference.

The polymer particles can include customary ingredients and additives,such as flame retardants, pigments, dyes, colorants, plasticizers, moldrelease agents, stabilizers, ultraviolet light absorbers, moldprevention agents, antioxidants, rodenticides, insect repellants, and soon. Typical pigments include, without limitation, inorganic pigmentssuch as carbon black, graphite, expandable graphite, zinc oxide,titanium dioxide, and iron oxide, as well as organic pigments such asquinacridone reds and violets and copper phthalocyanine blues andgreens.

In a particular embodiment of the invention the pigment is carbon black,a non-limiting example of such a material being EPS SILVER®, availablefrom NOVA Chemicals Inc.

In another particular embodiment of the invention the pigment isgraphite, a non-limiting example of such a material being NEOPOR®,available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein,Germany.

When materials such as carbon black and/or graphite are included in thepolymer particles, improved insulating properties, as exemplified byhigher R values for materials containing carbon black or graphite (asdetermined using ASTM-C578), are provided. As such, the R value of theexpanded polymer particles containing carbon black and/or graphite ormaterials made from such polymer particles are at least 5% higher thanobserved for particles or resulting articles that do not contain carbonblack and/or graphite.

The expanded polymer particles can have an average particle size of atleast 0.2, in some circumstances at least 0.3, in other circumstances atleast 0.5, in some cases at least 0.75, in other cases at least 0.9 andin some instances at least 1 mm and can be up to 8, in somecircumstances up to 6, in other circumstances up to 5, in some cases upto 4, in other cases up to 3, and in some instances up to 2.5 mm. Whenthe size of the expanded polymer particles is too small or too large,the physical properties of LWC articles made using the present LWCcomposition can be undesirable. The average particle size of theexpanded polymer particles can be any value and can range between any ofthe values recited above. The average particle size of the expandedpolymer particles can be determined using laser diffraction techniquesor by screening according to mesh size using mechanical separationmethods well known in the art.

In an embodiment of the invention, the polymer particles or expandedpolymer particles have a minimum average cell wall thickness, whichhelps to provide desirable physical properties to LWC articles madeusing the present LWC composition. The average cell wall thickness andinner cellular dimensions can be determined using scanning electronmicroscopy techniques known in the art. The expanded polymer particlescan have an average cell wall thickness of at least 0.15 μm, in somecases at least 0.2 μm and in other cases at least 0.25 μm. Not wishingto be bound to any particular theory, it is believed that a desirableaverage cell wall thickness results when resin beads having theabove-described dimensions are expanded to the above-describeddensities.

In an embodiment of the invention, the polymer beads are optionallyexpanded to form the expanded polymer particles such that a desirablecell wall thickness as described above is achieved. Though manyvariables can impact the wall thickness, it is desirable, in thisembodiment, to limit the expansion of the polymer bead so as to achievea desired wall thickness and resulting expanded polymer particlestrength. Optimizing processing steps and blowing agents can expand thepolymer beads to a minimum of 0.5 lb/ft³. This property of the expandedpolymer, bulk density, may be described by pcf (lb/ft³) or by anexpansion factor (cc/g).

As used herein, the term “expansion factor” refers to the volume a givenweight of expanded polymer bead occupies, typically expressed as cc/g.

In order to provide expanded polymer particles with desirable cell wallthickness and strength, the expanded polymer particles are not expandedto their maximum expansion factor; as such an extreme expansion yieldsparticles with undesirably thin cell walls and insufficient strength. Assuch, the polymer beads can be expanded at least 5%, in some cases atleast 10%, and in other cases at least 15% of their maximum expansionfactor. However, so as not to cause the cell wall thickness to be toothin, the polymer beads are expanded up to 80%, in some cases up to 75%,in other cases up to 70%, in some instances up to 65%, in otherinstances up to 60%, in some circumstances up to 55%, and in othercircumstances up to 50% of their maximum expansion factor. The polymerbeads can be expanded to any degree indicated above or the expansion canrange between any of the values recited above. Typically, the polymerbeads or prepuff beads do not further expand when formulated into thepresent cementitious compositions and do not further expand while thecementitious compositions set, cure and/or harden.

As used herein, the term “prepuff” refers to an expandable particle,resin and/or bead that has been expanded, but has not been expanded toits maximum expansion factor.

The prepuff or expanded polymer particles typically have a cellularstructure or honeycomb interior portion and a generally smoothcontinuous polymeric surface as an outer surface, i.e., a substantiallycontinuous outer layer. The smooth continuous surface can be observedusing scanning electron microscope (SEM) techniques at 1000×magnification. SEM observations do not indicate the presence of holes inthe outer surface of the prepuff or expanded polymer particles. Cuttingsections of the prepuff or expanded polymer particles and taking SEMobservations reveals the generally honeycomb structure of the interiorof the prepuff or expanded polymer particles.

The polymer particles or expanded polymer particles can have anycross-sectional shape that allows for providing desirable physicalproperties in LWC articles. In an embodiment of the invention, theexpanded polymer particles have a circular, oval or ellipticalcross-section shape. In embodiments of the invention, the prepuff orexpanded polymer particles have an aspect ratio of 1, in some cases atleast 1 and the aspect ratio can be up to 3, in some cases up to 2 andin other cases up to 1.5. The aspect ratio of the prepuff or expandedpolymer particles can be any valur or range between any of the valuesrecited above.

The cementitious mixture is present in the LWC composition at a level ofat least 22, in some cases at least 40 and in other cases at least 50volume percent and can be present at a level of up to 90, in somecircumstances up to 85, in other circumstances up to 80, in particularcases up to 75, in some cases up to 70, in other cases up to 65, and insome instances up to 60 volume percent of the LWC composition. Thecementitious mixture can be present in the LWC composition at any levelstated above and can range between any of the levels stated above.

In an embodiment of the invention, the cementitious mixture includes ahydraulic cement composition. The hydraulic cement composition can bepresent at a level of at least, in certain situations at least 5, insome cases at least 7.5, and in other cases at least 9 volume percentand can be present at levels up to 40, in some cases up to 35, in othercases up to 32.5, and in some instances up to 30 volume percent of thecementitious mixture. The cementitious mixture can include the hydrauliccement composition at any of the above-stated levels or at levelsranging between any of levels stated above.

In a particular embodiment of the invention, the hydraulic cementcomposition can be one or more materials selected from Portland cements,pozzolana cements, gypsum cements, aluminous cements, magnesia cements,silica cements, and slag cements.

In an embodiment of the invention, the cementitious mixture canoptionally include other aggregates and adjuvants known in the artincluding but not limited to sand, additional aggregate, plasticizersand/or fibers. Suitable fibers include, but are not limited to glassfibers, silicon carbide, aramid fibers, polyester, carbon fibers,composite fibers, fiberglass, and combinations thereof as well as fabriccontaining the above-mentioned fibers, and fabric containingcombinations of the above-mentioned fibers.

Non-limiting examples of fibers that can be used in the inventioninclude MeC-GRID® and C-GRID® available from TechFab, LLC, Anderson,S.C., KEVLAR® available from E.I. du Pont de Nemours and Company,Wilmington Del., TWARON® available from Teijin Twaron B.V., Arnheim, theNetherlands, SPECTRA® available from Honeywell International Inc.,Morristown, N.J., DACRON® available from Invista North America S.A.R.L.Corp. Willmington, Del., and VECTRAN® available from Hoechst CellaneseCorp., New York, N.Y. The fibers can be used in a mesh structure,intertwined, interwoven, and oriented in any desirable direction.

Further to this embodiment, the additional aggregate can include, but isnot limited to, one or more materials selected from common aggregatessuch as sand, stone, and gravel. Common lightweight aggregates caninclude ground granulated blast furnace slag, fly ash, glass, silica,expanded slate and clay; insulating aggregates such as pumice, perlite,vermiculite, scoria, and diatomite; LWC aggregate such as expandedshale, expanded slate, expanded clay, expanded slag, fumed silica,pelletized aggregate, extruded fly ash, tuff, and macrolite; and masonryaggregate such as expanded shale, clay, slate, expanded blast furnaceslag, sintered fly ash, coal cinders, pumice, scoria, and pelletizedaggregate.

When included, the other aggregates and adjuvants are present in thecementitious mixture at a level of at least 0.5, in some cases at least1, in other cases at least 2.5, in some instances at least 5 and inother instances at least 10 volume percent of the cementitious mixture.Also, the other aggregates and adjuvants can be present at a level of upto 95, in some cases up to 90, in other cases up to 85, in someinstances up to 65 and in other instances up to 60 volume percent of thecementitious mixture. The other aggregates and adjuvants can be presentin the cementitious mixture at any of the levels indicated above or canrange between any of the levels indicated above.

The cementitious mixture, expanded polymer particles, and any otheraggregates and adjuvants are mixed using methods well known in the art.In an embodiment of the invention a liquid, in some instances water, isalso mixed into the other ingredients.

In an embodiment of the invention, the concrete composition is adispersion where the cementitious mixture provides, at least in part, acontinuous phase and the polymer particles and/or expanded polymerparticles exist as a dispersed phase of discrete particles in thecontinuous phase.

As a particular and non-limiting embodiment of the invention, theconcrete composition is substantially free of wetting agents ordispersing agents used to stabilize the dispersion.

As a non-limiting embodiment of the invention and as not wishing to belimited to any single theory, some key factors that can affect theperformance of the present LWC composition can include the volumefraction of the expanded resin bead, the average expanded bead size andthe microstructure created by the inter-bead spacing within theconcrete. In this embodiment, the inter-bead spacing can be estimatedusing a two-dimensional model. For simplicity in description, theinter-bead spacing can be limited to the bead radius. Additionally, andwithout meaning to limit the invention in any way, it is assumed in thisembodiment that the beads are arranged in a cubic lattice, bead sizedistribution in the LWC composition is not considered, and thedistribution of expanded bead area in the cross-section is notconsidered. In order to calculate the number of beads per sample, athree-dimensional test cylinder is assumed.

The smaller the expanded bead size, the greater the number of expandedbeads required to maintain the same expanded bead volume fraction asdescribed by equation 1 below. As the number of expanded beads increasesexponentially, the spacing between the expanded beads decreases.N _(b) =K/B ³  (1)N_(b) represents the number of expanded beads.

A LWC test specimen with diameter D and height H (usually 2″×4″ or6″×12″), containing dispersed expanded polymer beads of average expandedbead diameter B, and a given volume fraction V_(d) contains an amount ofexpanded polymer beads N_(b) given by equation 1:

Note that N_(b) is inversely proportional to the cube of the expandedpolymer bead diameter. The constant of proportionality, K=1.5 V_(d)HD²,is a number that is dependent only on the sample size and the volumefraction of expanded polymer beads. Thus for a given sample size, andknown expanded polymer bead volume fraction, the number of beadsincreases to a third power as the bead diameter decreases.

As a non-limiting example, for a 2″×4″ LWC specimen, at 90 pcf (lb/ft³)(corresponding to expanded polymer bead 43% volume fraction withpre-puff bulk density of 1.25 pcf), the number of beads increasesfourfold and sevenfold moving from a 0.65 mm bead to 0.4 mm and 0.33 mmbeads respectively. At 2.08 pcf, the increase in the number of beads issixfold and sevenfold for 0.4 mm and 0.33 mm beads respectively. At 5pcf, the increases are twofold and threefold respectively. Thus, thedensity correlates to the bead size. As shown below, the density alsoaffects the cell wall thickness. The strength of a concrete matrixpopulated by expanded beads is typically affected by the cell wallstiffness and thickness.

In an embodiment of the invention, where monodisperse spherical cellsare assumed, it can be shown that the mean cell diameter d is related tothe mean wall thickness δ by equation 2:

$\begin{matrix}{d = {\delta/\left( {\frac{1}{\sqrt{1 - {\rho/\rho_{s}}}} - 1} \right)}} & (2)\end{matrix}$where ρ is the density of the foam and ρ_(s) is the density of the solidpolymer bead.

Thus for a given polymer, depending on the particular expansion processused, one can obtain the same cell wall thickness (at a given cell size)or the same cell size at various values of δ. The density is controllednot only by the cell size but also by varying the thickness of the cellwall.

The table below exemplifies the variation of expanded polymer beaddensity with bead size for three classes of beads.

Foam Expansion Average Number Bead Size, Density Particle factor ofbeads for 43% microns (pcf) Size (mm) (cc/g) volume fraction 650 2.001.764 31 96,768 650 3.00 1.541 21 145,152 650 4.00 1.400 16 193,536 4002.00 1.086 31 415,233 400 3.00 0.949 21 622,849 400 4.00 0.862 16830,466 330 2.00 0.896 31 739,486 330 3.00 0.783 21 1,109,229 330 4.000.711 16 1,478,972

Desirable microstructures and/or morphologies can fall into distinctclasses. The first is a bicontinous or co-continuous composite withspecial interfaces and the second comprises of special inclusions in aconnected matrix. The effective properties of both bicontinous andsingly connected microstructures are described by known optimalcross-property bounds.

In many cases, the smaller the beads, the greater the number of beadsrequired to maintain the same expanded polymer bead volume fraction asdescribed by equation 1. As the number of beads increases exponentially,the spacing between the beads decreases.

The optimal bounds can be described by a number of relationsrepresenting critical numbers or limits. As a non-limiting example, fora given volume fraction, there is often a critical bead sizecorresponding to a critical number of beads that can be dispersed toprovide a desired morphology such that all the beads are isolated andthe concrete is singly connected. It is also possible to form amorphology where all of the beads are non-isolated but contacting.

Finite element analysis of a 2-dimensional cross section was performedusing ANSYS® (a finite element analysis program available from ANSYSInc., Canonsburg, Pa.). In the finite element mesh of the cross-section,the beads are modeled as non-contacting or isolated circles in a singlyconnected concrete matrix.

The results demonstrate that under loading, the stresses build up in adirection perpendicular to the load axis. The maximum stressconcentrations are at the horizontal boundary between the expandedpolymer beads, which tend to be deformed from a circular shape to anelliptical shape.

In a particular embodiment of the invention, the concrete compositioncontains at least some of the expanded polymer particles arranged in acubic or hexagonal lattice.

In an embodiment of the invention, the present LWC composition issubstantially free of air entraining agents, which are typically addedto create air cells or voids in a batch of concrete.

In another embodiment of the invention, the LWC composition can includereinforcement fibers. Such fibers act as reinforcing components, havinga large aspect ratio, that is, their length/diameter ratio is high, sothat a load is transferred across potential points of fracture.Non-limiting examples of suitable fibers include fiberglass strands ofapproximately one to one and three fourths inches in length, althoughany material can be used that has a higher Young's modulus than thematrix of the cementitious mixture, polypropylene fiber and other fibersas described above.

The LWC compositions according to the invention can be set and/orhardened to form final concrete articles using methods well known in theart.

The density of the set and/or hardened final concrete articlescontaining the LWC composition of the invention can be at least 40lb/ft³ (0.64 g/cc), in some cases at least 45 lb/ft³ (0.72 g/cc) and inother cases at least 50 lb/ft³ (0.8 g/cc) lb/ft³ and the density can beup to 130 lb/ft³ (2.1 g/cc), in some cases 120 lb/ft³ (1.9 g/cc), inother cases up to 115 lb/ft³ (1.8 g/cc), in some circumstances up to 110lb/ft³ (1.75 g/cc), in other circumstances up to 105 lb/ft³ (1.7 g/cc),in some instances up to 100 lb/ft³ (1.6 g/cc), and in other instances upto 95 lb/ft³ (1.5 g/cc). The density of the present concrete articlescan be any value and can range between any of the values recited above.

The LWC compositions can be used in most, if not all, applications wheretraditional concrete formulations are used. As non-limiting examples,the present LWC compositions can be used in structural and architecturalapplications, non-limiting examples being party walls, ICF or SIPstructures, bird baths, benches, shingles, siding, drywall, cementboard, decorative pillars or archways for buildings, etc., furniture orhousehold applications such as counter tops, in-floor radiant heatingsystems, floors (primary and secondary), tilt-up walls, sandwich wallpanels, as a stucco coating, road and airport safety applications suchas arresting walls, Jersey Barriers, sound barriers and walls, retainingwalls, runway arresting systems, air entrained concrete, runaway truckramps, flowable excavatable backfill, and road construction applicationssuch as road bed material and bridge deck material.

Additionally, LWC articles according to the invention readily acceptdirect attachment of screws, as a non-limiting example drywall screwsand nails, which can be attached by traditional, pneumatic, or powderactuated devices. This allows easy attachment of materials such asplywood, drywall, studs and other materials commonly used in theconstruction industry, which cannot be done using traditional concreteformulations.

When the LWC compositions of the invention are used in road bedconstruction, the polymer particles can aid in preventing and orminimizing crack propagation, especially when water freeze-thaw isinvolved.

In an embodiment of the invention, the set and/or hardened LWCcompositions according to the invention are used in structuralapplications and can have a minimum compressive strength for loadbearing masonry structural applications of at least 1500 psi (105.5kgf/cm²), in some cases at least 1700 psi (119.5 kgf/cm²), in othercases at least 1800 psi (126.5 kgf/cm²), in some instances at least 1900psi, and in other instances at least 2000 psi (140.6 kgf/cm²). Forstructural lightweight concrete the compositions can have a minimumcompressive strength of at least 2500 psi (175.8 kgf/cm²). Compressivestrengths are determined according to ASTM C39.

The compositions of the invention are well suited to the fabrication ofmolded construction articles and materials, non-limiting examples ofsuch include wall panels including tilt-up wall panels, T beams, doubleT beams, roofing tiles, roof panels, ceiling panels, floor panels, Ibeams, foundation walls and the like. The compositions exhibit greaterstrength than prior art LWC compositions.

In an embodiment of the invention, the molded construction articles andmaterials can be pre-cast and/or pre-stressed.

A particular advantage that the present invention provides is that theset concrete composition and/or molded construction articles formed fromsuch compositions can be readily cut and/or sectioned using conventionalmethods as opposed to having to use specialized concrete or diamondtipped cutting blades and/or saws. This provides substantial time andcost savings when customizing concrete articles.

The compositions can be readily cast into molds according to methodswell known to those of skill in the art for roofing tiles in virtuallyany three dimensional configuration desired, including configurationshaving certain topical textures such as having the appearance of woodenshakes, slate shingles or smooth faced ceramic tiles. A typical shinglecan have approximate dimensions of ten inches in width by seventeeninches in length by one and three quarters inches in thickness. In themolding of roofing materials, the addition of an air entrainment agentmakes the final product more weatherproof in terms of resistance tofreeze/thaw degradation.

When foundation walls are poured using the LWC compositions of theinvention, the walls can be taken above grade due to the lighter weight.Ordinarily, the lower part of the foundation wall has a tendency to blowoutwards under the sheer weight of the concrete mixture, but the lighterweight of the compositions of the invention tend to lessen the chancesof this happening. Foundation walls prepared using the present LWCcompositions can readily take conventional fasteners used inconventional foundation wall construction.

Embodiments of the present invention provide a stay in place insulatingconcrete forming system that is continuous in nature with length beinglimited only by transportation and handling limitations, where thepresent lightweight concrete composition is poured and allowed to set inthe insulating concrete forming system. The present insulating concreteforming system includes two opposing foamed plastic faces, containing anexpanded polymer matrix, connected internally and spaced apart byperforated structural metal members. The foamed plastic faces and metalspacing members are aligned within the form to properly positionvertically and horizontally concrete reinforcement steel, while allowingfor proper concrete flow and finish work attachments. The molded instructural steel members act as internal bracing keeping the formsstraight and aligned during concrete placement eliminating the need formost external blocking.

Further, the present invention provides pre-formed insulated concreteforms, into which the present lightweight concrete composition can beformed, that include one or more reinforcing structural elements or barsrunning longitudinally, the end of which are at least partially embeddedin oppositely facing expanded polymer bodies. The remainder of thereinforcing structural element(s), the portion between the expandedpolymer bodies, are at least partially exposed. The portions of the endsthat are encapsulated in the expanded polymer matrix can provide athermal break from the external environment. The reinforcing structuralelements can be flanged lengthwise on either side to provide attachmentpoints for external objects to the panel. Perforations in thereinforcing structural elements in the end portions which areencapsulated in the expanded polymer matrix allow for fusion of theexpandable polymer particles perpendicularly. Perforations in theexposed portion of the reinforcing structural element provide attachmentpoints for lateral bracing and/or rebar and allow for uniform concreteflow when concrete is poured into the present insulated concrete form. Atongue and groove or overlapping connection point design provides forpanel abutment while maintaining the integrity of the concrete form.Longitudinal holes can run through the expanded polymer matrix and canbe variable in diameter and location to provide areas for placement ofutilities, lightening the structure and channels for venting of gasses.Panel manufacture is accomplished through the use of a semi-continuousor continuous molding process allowing for variable panel lengths.

The embedded framing studs or floor joists used in the invention can bemade of any suitable material. Suitable materials are those that addstrength, stability and structural integrity to the pre-formed buildingpanels. Such materials provide embedded framing studs meeting therequirements of applicable test methods known in the art, asnon-limiting examples ASTM A 36/A 36M-05, ASTM A 1011/A 1011 M-05a, ASTMA 1008/A 1008M-05b, and ASTM A 1003/A 1003M-05 for various types ofsteel.

Suitable materials include, but are not limited to metals, constructiongrade plastics, composite materials, ceramics, combinations thereof, andthe like. Suitable metals include, but are not limited to, aluminum,steel, stainless steel, tungsten, molybdenum, iron and alloys andcombinations of such metals. In a particular embodiment of theinvention, the metal bars, studs, joists and/or members are made of alight gauge metal.

Suitable construction grade plastics include, but are not limited toreinforced thermoplastics, thermoset resins, and reinforced thermosetresins. Thermoplastics include polymers and polymer foams made up ofmaterials that can be repeatedly softened by heating and hardened againon cooling. Suitable thermoplastic polymers include, but are not limitedto homopolymers and copolymers of styrene, homopolymers and copolymersof C₂ to C₂₀ olefins, C₄ to C₂₀ dienes, polyesters, polyamides,homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters,polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides,polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their curepoint, undergo a chemical cross-linking reaction causing them tosolidify and hold their shape rigidly, even at elevated temperatures.Suitable thermoset resins include, but are not limited to alkyd resins,epoxy resins, diallyl phthalate resins, melamine resins, phenolicresins, polyester resins, urethane resins, and urea, which can becrosslinked by reaction, as non-limiting examples, with diols, triols,polyols, and/or formaldehyde.

Reinforcing materials and/or fillers that can be incorporated into thethermoplastics and/or thermoset resins include, but are not limited tocarbon fibers, aramid fibers, glass fibers, metal fibers, woven fabricor structures of the mentioned fibers, fiberglass, carbon black,graphite, clays, calcium carbonate, titanium dioxide, woven fabric orstructures of the above-referenced fibers, and combinations thereof.

A non-limiting example of construction grade plastics are thermosettingpolyester or vinyl ester resin systems reinforced with fiberglass thatmeet the requirements of required test methods known in the art,non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTMD638.

The thermoplastics and thermoset resins can optionally include otheradditives, as a non-limiting example ultraviolet (UV) stabilizers, heatstabilizers, flame retardants, structural enhancements, biocides, andcombinations thereof.

In a particular embodiment of the invention, the embedded framing studsor embedded floor joists are made of a light gauge metal.

The embedded studs or embedded floor joists described herein can have athickness of at least 0.4 mm, in some cases at least 0.5 mm, in othercases at least 0.75 mm, in some instances at least 1 mm, in otherinstances at least 1.25 mm and in some circumstances at least 1.5 mm andcan have a thickness of at least 10 mm, in some cases at least 8 mm, inother cases at least 6 mm, in some instances at least 4 mm and in othercases at least 2 mm. The thickness of the embedded studs or embeddedfloor joists will depend on the intended use of the pre-formed buildingpanel.

In an embodiment of the invention, the embedded framing studs orembedded floor joists have holes or openings along their length tofacilitate fusion of the expanded plastic material and to reduce anythermal bridging effects in the reinforcing bars, studs, joists and/ormembers.

In the present invention, the foamed plastic faces can be molded fromany suitable expandable plastic material, as described above, on amolding machine capable of inserting the metal members and forming twoopposing face panels while maintaining the composite materials in theirrelative position in a continuous or semi continuous process.

The expanded polymer matrix makes up the expanded polymer body describedherein below. The expanded polymer matrix is typically molded fromexpandable thermoplastic particles. These expandable thermoplasticparticles are made from any suitable thermoplastic homopolymer orcopolymer. Particularly suitable for use are homopolymers derived fromvinyl aromatic monomers including styrene, isopropylstyrene,alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene,tert-butylstyrene, and the like, as well as copolymers prepared by thecopolymerization of at least one vinyl aromatic monomer as describedabove with one or more other monomers, non-limiting examples beingdivinylbenzene, conjugated dienes (non-limiting examples beingbutadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates, alkylacrylates, acrylonitrile, and maleic anhydride, wherein the vinylaromatic monomer is present in at least 50% by weight of the copolymer.In an embodiment of the invention, styrenic polymers are used,particularly polystyrene. However, other suitable polymers can be used,such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates,polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the expandablethermoplastic particles are expandable polystyrene (EPS) particles.These particles can be in the form of beads, granules, or otherparticles convenient for the expansion and molding operations. Particlespolymerized in an aqueous suspension process are essentially sphericaland are useful for molding the expanded polymer body described hereinbelow. These particles can be screened so that their size ranges fromabout 0.008 inches (0.2 mm) to about 0.1 inches (2.5 mm).

The expandable thermoplastic particles can be impregnated using anyconventional method with a suitable blowing agent. As a non-limitingexample, the impregnation can be achieved by adding the blowing agent tothe aqueous suspension during the polymerization of the polymer, oralternatively by re-suspending the polymer particles in an aqueousmedium and then incorporating the blowing agent as taught in U.S. Pat.No. 2,983,692. Any gaseous material or material which will produce gaseson heating can be used as the blowing agent. Conventional blowing agentsinclude aliphatic hydrocarbons containing 4 to 6 carbon atoms in themolecule, such as butanes, pentanes, hexanes, and the halogenatedhydrocarbons, e.g. CFC's and HCFC'S, which boil at a temperature belowthe softening point of the polymer chosen. Mixtures of these aliphatichydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbonsblowing agents or water can be used as the sole blowing agent as taughtin U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents,water-retaining agents are used. The weight percentage of water for useas the blowing agent can range from 1 to 20%. The texts of U.S. Pat.Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein byreference.

The impregnated thermoplastic particles are generally pre-expanded to adensity of at least 0.5 lb/ft³ (0.008 g/cc), in some cases at least 1lb/ft³ (0.016 g/cc), in other cases at least 1.25 lb/ft³ (0.02 g/cc), insome situations at least 1.5 lb/ft³ (0.024 g/cc), in other situations atleast 2 lb/ft³ (0.032 g/cc), and in some instances at least about 3lb/ft³ (0.048 g/cc). Also, the density of the impregnated pre-expandedparticles can be up to 35 lb/ft³ (0.56 g/cc), in some cases up to 30lb/ft³ (0.48 g/cc), and in other cases up to 25 lb/ft³ (0.4 g/cc). Thedensity of the impregnated pre-expanded particles can be any value orrange between any of the values recited above. The pre-expansion step isconventionally carried out by heating the impregnated beads via anyconventional heating medium, such as steam, hot air, hot water, orradiant heat. One generally accepted method for accomplishing thepre-expansion of impregnated thermoplastic particles is taught in U.S.Pat. No. 3,023,175.

The impregnated thermoplastic particles can be foamed cellular polymerparticles as taught in U.S. patent application Ser. No. 10/021,716, theteachings of which are incorporated herein by reference. The foamedcellular particles can be polystyrene that are pre-expanded and containa volatile blowing agent at a level of less than 6.0 weight percent, insome cases ranging from about 2.0 wt % to about 5.0 wt %, and in othercases ranging from about 2.5 wt % to about 3.5 wt % based on the weightof the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromaticmonomers that can be included in the expandable thermoplastic resinaccording to the invention is disclosed in U.S. Pat. Nos. 4,303,756 and4,303,757 and U.S. Application Publication 2004/0152795, the relevantportions of which are herein incorporated by reference. A non-limitingexample of interpolymers that can be used in the present inventioninclude those available under the trade name ARCEL®, available from NOVAChemicals Inc., Pittsburgh, Pa. and PIOCELAN®, available from SekisuiPlastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix can include customary ingredients andadditives, such as pigments, dyes, colorants, plasticizers, mold releaseagents, stabilizers, ultraviolet light absorbers, mold preventionagents, antioxidants, and so on. Typical pigments include, withoutlimitation, inorganic pigments such as carbon black, graphite,expandable graphite, zinc oxide, titanium dioxide, and iron oxide, aswell as organic pigments such as quinacridone reds and violets andcopper phthalocyanine blues and greens.

In a particular embodiment of the invention the pigment is carbon black,a non-limiting example of such a material being EPS SILVER®, availablefrom NOVA Chemicals Inc.

In another particular embodiment of the invention the pigment isgraphite, a non-limiting example of such a material being NEOPOR®,available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein,Germany.

The pre-expanded particles or “pre-puff” are heated in a closed mold inthe semi-continuous or continuous molding process described below toform the pre-formed building panels according to the invention.

The pre-formed building panels used in the present invention can be madeusing batch shape molding techniques. However, this approach can lead toinconsistencies and can be very time intensive and expensive.

Alternatively, the foamed plastic faces can be molded from any suitableexpandable plastic material, as described above, on a molding machinecapable of inserting the metal members and forming two opposing facepanels while maintaining the composite materials in their relativeposition in a continuous or semi continuous process.

The pre-formed building panels used to make the ICF units and otherbuilding panels described herein can be made using an apparatus formolding a semi-continuous or continuous foamed plastic element thatincludes

a) One or more molds that include:

-   -   i) a bottom wall, a pair of opposite side walls and a cover, and    -   ii) a molding seat, having a shape mating that of the element,        defined in the mold between the side walls, the bottom wall and        the cover;

b) means for displacing the covers and the side walls of the moldstowards and away from the bottom wall to longitudinally close andrespectively open the mold; and

c) first means for positioning in an adjustable manner said covers awayfrom and towards said bottom wall of the mold to control in anadjustable and substantially continuous manner the height of the moldingseat.

The apparatus is configured to include the embedded framing studs orembedded floor joists configured as discussed herein. As a non-limitingexample, the methods and apparatus disclosed in U.S. Pat. No. 5,792,481can be adapted to make the ICF units, of the present invention. Therelevant parts of U.S. Pat. No. 5,792,481 are incorporated herein byreference.

More particularly, the present insulated concrete form includes a firstbody, substantially parallelepipedic in shape, containing an expandedpolymer matrix, having opposite faces, a first surface, and an opposingsecond surface; a second body, substantially parallelepipedic in shape,containing an expanded polymer matrix, having opposite faces, a firstsurface, an opposing second surface; and one or more embedded studslogitudinally extending across the first body and the second bodybetween the first surfaces of each body, having a first end embedded inthe expanded polymer matrix of the first body, and a second end embeddedin the expanded polymer matrix of the second body. One or more expansionholes are provided in the portion of the embedded stud embedded in thefirst body and the second body. The first body and the second bodyinclude a polymer matrix that expands through the expansion holes. Thespace defined between the first surfaces of the first body and thesecond body is capable of accepting concrete poured therein.

An embodiment of the present invention provides insulated concrete forms(ICF) and ICF systems. As shown in FIG. 1, ICF 510 includes firstexpanded polymer body 511 and second expanded polymer body 512, leftfacing embedded metal studs 514, and right facing embedded metal studs516 (reinforcing embed bars). The embedded metal studs 514 and 516 haveembedded ends 520 and 522 respectively that do not touch outer surface524 of first expanded polymer body 511. Embedded metal studs 514 and 516have embedded ends 521 and 523 respectively that are adjacent to outersurface 525 of second expanded polymer body 512. Space 505 is defined asthe space between inner surface 530 of first expanded polymer body 511and inner surface 531 of second expanded polymer body 512 for the heightof ICF 510.

Expanded polymer bodies 511 and 512 can have a thickness, measured asthe distance from inner surface 530 or 531 respectively to outer surface524 or 525 respectively of at least 2, in some cases at least 2.5, andin other cases at least 3 cm and can be up to 10, in some cases up to 8,and in other cases up to 6 cm from inner surface 30 of expanded polymerbody 512. The thickness of expanded polymer bodies 511 and 512 canindependently be any dimension or range between any of the dimensionsrecited above.

Embedded ends 520 and 522 extend at least 1, in some cases at least 2,and in other cases at least 3 cm into expanded polymer body 512 awayfrom inner surface 530. Also, Embedded ends 520 and 522 can extend up to10, in some cases up to 8, and in other cases up to 6 cm away from innersurface 530 into first expanded polymer body 511. Embedded ends 526 and528 can extend any of the distances or can range between any of thedistances recited above from inner surface 530 into polymer body 511.

In another embodiment of the invention, embedded ends 520 and 522 canextend from 1/10 to 9/10, in some cases ⅓ to ⅔ and in other cases ¼ to ¾of the thickness of first expanded polymer body 511 into expandedpolymer body 511.

The orientation of embedded metal studs 514 and 516 is referenced by thedirection of ends 520, 521, 522, and 523. The ends can be oriented inany direction that suits the strength, attachment objectives orstability of the insulated concrete form.

The spacing between each of embedded metal studs 514 and 516 istypically adapted to be consistent with local construction codes ormethods, but can be modified to suit special needs. As such, the spacingbetween the metal studs can be at least 10, in some instances at least25 and in some cases at least 30 cm and can be up to 110, in some casesup to 100, in other cases up to 75, and in some instances up to 60 cm.The spacing between embedded metal studs 514 and 516 can be any distanceor range between any of the distances recited above.

ICF 510 can extend for a distance with alternating embedded metal studs514 and 516 placed therein. The length of ICF 510 can be any length thatallows for safe handling and minimal damage to ICF 510. The length ofICF 510 can typically be at least 1, in some cases at least 1.5, and inother cases at least 2 m and can be up to 25, in some cases up to 20, inother cases up to 15, in some instances up to 10 and in other instancesup to 5 m. The length of ICF 510 can be any value or can range betweenany of the values recited above. In some embodiments of the invention,each end of ICF 510 is terminated with an embedded metal stud.

The height of ICF 510 can be any height that allows for safe handling,minimal damage, and can withstand the pressure from concrete pouredwithin ICF 510. The height of ICF 510 can be at least 1 and in somecases at least 1.25 m and can be up to 3 M and in some cases up to 2.5m. In some instances, in order to add stability to ICF unit 510,reinforcing cross-members or rebar (not shown) can be attached toembedded metal studs 514 and 516. The height of ICF 10 can be any valueor can range between any of the values recited above.

Space 505, the space between inner surface 530 and inner surface 531 forthe height of ICF 510, can be any suitable volume and/or dimensions.Suitable volume and/or dimensions are those where the weight of thelightweight concrete poured into space 505 is not so high as to causeany part of ICF 510 to fail, i.e., allow concrete to break through ICF510 such that the volume of concrete is not contained in space 505, butlarge enough that the poured and set concrete can support whatever is tobe built on the resulting ICF concrete wall. Thus, the distance betweeninner surface 530 and inner surface 531 taken with the height definedabove can be at least 5 in some cases at least 10 and in other cases atleast 12 cm and can be up to 180, in some cases up to 150 cm and inother cases up to 120 cm. In some instances, in order to add stabilityto ICF unit 510, reinforcing cross-members or rebar (not shown) can beattached to embedded metal studs 514 and 516. The distance between innersurface 530 and inner surface 531 can be any value or can range betweenany of the values recited above.

In a particular embodiment of the invention, ICF 510 can be used as astorm wall. In this embodiment, space 505 is filled with the presentlightweight concrete composition as described herein and the distancefrom inner surface 530 to inner surface 531 can be at least 2 in somecases at least 5 and in other cases at least 10 cm and can be up to 16,in some cases up to 14 cm and in other cases up to 12 cm. In this stormwall embodiment, the distance between inner surface 530 and innersurface 531 can be any value or can range between any of the valuesrecited above.

Storm walls made according to the present invention can be used as anyof the other wall panels and tilt-up walls described herein.

As shown in FIG. 1, ICF 510 has a finite length and first body 511 andsecond body 512 have an inner lip terminus 517 and an outer lip terminus518. Typically, lengths of ICF 510 are interconnected by inserting aninner lip terminus 517 of one ICF 510 adjacent an outer lip terminus 518of another ICF 510 to form a continuous ICF. Thus, a larger ICFcontaining any number of ICF 510 units can be assembled and/or arrayed.

An alternative embodiment of the invention is shown in FIG. 2, where ICF508 is similar to ICF 510 except that inner surface 530 of body 511 andinner surface 531 of body 512 include oppositely opposed inner archingsections 532 and 534 respectively. Inner arching sections 532 and 534provide a non-linear space within ICF 508, such that lightweightconcrete poured into ICF 508 will have sections that have a largercross-sectional width and sections having a smaller cross-sectionalwidth.

In another embodiment of the invention shown in FIG. 3, ICF 509 hasexposed ends 536 and 538 instead of embedded ends 521 and 523. Exposedends 536 and 538 extend at least 1, in some cases at least 2, and inother cases at least 3 cm away from outer surface 525 of second expandedpolymer body 512. Exposed ends 536 and 538 can be used to attach finishsurfaces, such as drywall, plywood, paneling, etc. as described hereinto ICF 509. Also, Exposed ends 536 and 538 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer surface525 of expanded polymer body 512. Exposed ends 536 and 538 can extendany of the distances or can range between any of the distances recitedabove from outer surface 525.

Referring to FIG. 3 embedded metal studs 514 and 516 can have utilityholes (as described below) spaced along their length between outersurface 525 and exposed ends 536 and 538. The utility holes (not shownhere, but as described and illustrated below) are useful foraccomodating utilities such as wiring for electricity, telephone, cabletelevision, speakers, and other electronic devices, gas lines and waterlines. The utility holes can have various cross-sectional shapes,non-limiting examples being round, oval, elliptical, square,rectangular, triangular, hexagonol or octagonal. The cross-sectionalarea of the utility holes can also vary independently one from anotheror they can be uniform. The cross-sectional area of the utility holes islimited by the dimensions of embedded metal studs 514 and 516, as theutility holes will fit within their dimensions and not significantlydetract from their structural integrity and strength. Thecross-sectional area of the utility holes can independently be at least1, in some cases at least 2, and in other cases at least 5 cm² and canbe up to 30, in some cases up to 25, in other cases up to 20 cm². Thecross-sectional area of the utility holes can independently be any valueor range between any of the values recited above.

In an embodiment of the invention, the utility holes can have a flangedand in many cases a rolled flange surface to provided added strength tothe embedded metal studs.

FIGS. 4 and 5 show features of the present ICF and storm panels as theyrelate to ICF 508 (FIG. 2). A feature of embedded metal studs 514 and516 is that they can include expansion holes 540 and pour holes 542. Assuch pour holes 544 can be a punched hole extending along the verticalaxis of embedded metal studs 514 and/or 516 that is positioned to allowthe free flow of the lightweight concrete and to fix and positionhorizontal concrete reinforcements. Similarly, expansion holes 540 canbe a punched hole of sufficient diameter or slot of sufficient void areato allow the fusion and flow of the polymer matrix through the formedplastic panel.

The molded in light gauge metal structural members, embedded metal studs514 and 516, can be continuously or semi continuously formed to create acomposite panel of unlimited length. The structural metal members arestrategically punched along the outer vertical axis to provide expansionholes 540, which allow for the flow of and fusion of the expandableplastic materials through the metal members. The center vertical axis ofthe metal member is punched to provide pour holes 542, which permit thefree flow of normal concrete and to aid in the fixing and placement ofhorizontal concrete reinforcement materials. FIGS. 6 and 7 show theformed and set lightweight concrete 550 in relation to embedded metalstuds 514.

Embedded ends 521 and 523 act as continuous furring strips runningvertically on predetermined centers to aid in the direct connection offinish materials, top and bottom structural tracks, wall penetrationsand roof and floor connection points, such as the level track describedherein.

The expandable plastic materials in the composite panel acts as aforming panel when lightweight concrete is placed within the form andcan also provides insulation and sound deadening. Further, theexpandable plastic materials face of the composite panel acts as aforming panel when concrete is placed within the form and also providesinsulation and sound deadening.

The design of the present ICF provides horizontal and vertical concretepathways created by the two opposing face panels fixed by the lightgauge structural members.

When lightweight concrete is poured into space 505 of the present ICF,an internal concrete post is formed by the two opposing face panelswithin the vertical post wall configuration of the panel design, setlightweight concrete 550. The concrete core created in the form acts ashorizontal bracing to the light-gauge structural metal members in thepresent ICF. In the vertical post wall panel design the concrete coreallows for horizontal reinforcement along the axis of the vertical postcreated between the form face panels.

In the present ICF, the interlocking panel ends formed by inner lip 517and outer lip 518 are self aligning, self sealing and securely connectone panel side termination to the other panel side termination point,forming a continuous horizontal as well as continuous vertical concreteplacement form.

FIG. 8 shows an embodiment of the invention where the surface of steelmember 560, which can be used as embedded metal studs 514 and/or 516 inthe present ICF have dimples 565 in opposing directions creating asurface that increases concrete adhesion and prevents cracking of theconcrete in contact with steel member 560. The dimple effect on themember surface adds to the shear resistance of the steel and concretecomposition. The dimpling of the steel surface creates a strongerconnection between the foam and the steel member of the plastic foamfaces of the panel when molded as a composite structure.

FIG. 9 shows an embodiment of an insulated concrete form system 575 forproviding a foundation that includes a plurality of ICF's 508 connectedend to end to form ICF system 575. Corner unit 552 is used tointerconnect parallel ICF lines 554 and perpendicular ICF lines 556.Lightweight concrete is poured into space 505 of ICF wall system 575 andallowed to set to form a completed insulated concrete wall system.

Corner unit 552, as shown in FIG. 10 essentially includes a first ICF508A and a second ICF 508B (like features are numbered as above)oriented at an angle to first ICF 508A, where corner section 552 ismolded to include first ICF 508A and second ICF 508B to form acontinuous first body 590 and a continuous second body 592 and providinga continuous space 505 there between.

Referring to FIG. 3, a particular advantages of ICF 509 includes theability to easily run utilities prior to attaching a finish surface tothe exposed ends of the embedded metal studs. The exposed metal studsfacilitate field structural framing changes and additions and leave thestructural portions of the assembly exposed for local building officialsto inspect the framing.

A utility space defined by outer surface 525 of expanded polymer body512 and exposed ends 536 and 538 can be adapted for accommodatingutilities. Typically, exposed ends 536 and 538 have a finish surfaceattached to them, a side of which further defines the utility space.

In an embodiment of the invention, the utility space is adapted anddimensioned to receive standard and/or pre-manufactured components, suchas windows, doors and medicine cabinets as well as customized cabinetsand shelving.

Further, the air space between the outer surface of the expanded polymerbody 512 and the finish surface allows for improved air circulation,which can minimize or prevent mildew. Additionally, because the metalstuds are not in direct contact with the outside environment, thermalbridging via the highly conductive embedded metal studs is avoided andinsulation properties are improved.

Suitable finish surfaces include, but are not limited to finish surfacessuch as wood, rigid plastics, wood paneling, concrete panels, cementpanels, drywall, sheetrock, particle board, rigid plastic panels, or anyother suitable material having decorating and/or structural functions orother construction substrates

In a particular type of wall construction useful in the invention usesfoam plastic walls to form a sandwich structure containing the pouredLWC composition. After hardening, the foam walls are left intact to addsignificantly to the insulation properties of the walls. Such walls canbe made of extruded or expanded polymer particles as described above orthe like, and frequently are available to contractors in preformed walland corner units that snap or clip together, according to methods wellknown to those in the construction trades.

An embodiment of the invention relates to a tilt up insulated panel thatis adapted for use as a wall or ceiling panel. As shown in FIGS. 11-14,one-sided wall panel 340 includes a reinforced body 341 that includesexpanded polymer form 342 (central body) and embedded metal studs 344and 346 (embedded reinforcing bars). Expanded polymer form 342 caninclude openings 348 and utility chases 349, which traverse all or partof the length of expanded polymer form 342. The embedded metal studs 344and 346 have embedded ends 352 and 356 respectively that are not incontact with inner face 350 of expanded polymer form 342. The embeddedmetal studs 344 and 346 also have exposed ends 358 and 360 respectivelythat extend from outer face 362 of expanded polymer form 342.

Expanded polymer form 342 can have a thickness, measured as the distancefrom inner face 350 to outer face 362 of at least 8, in some cases atleast 10, and in other cases at least 12 cm and can be up to 100, insome cases up to 75, and in other cases up to 60 cm. The thickness ofexpanded polymer form 342 can be any distances or can range between anyof the distances recited above.

Exposed ends 358 and 360 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away outer face 362 of expanded polymerform 342. Also, Exposed ends 358 and 360 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer face 362of expanded polymer form 342. Exposed ends 358 and 360 can extend any ofthe distances or can range between any of the distances recited abovefrom outer face 362.

In an embodiment of the invention, embedded metal studs members 344 and346 have a cross-sectional shape that includes embedding lengths 364 and366, embedded ends 352 and 356, and exposed ends 358 and 360. Theorientation of embedded metal studs members 344 and 346 is referenced bythe direction of embedded ends 352 and 356. In a particular embodimentof the invention, embedded ends 352 and 356 are oriented away from eachother. In this embodiment, one-sided wall panel 340 is adapted so thatexposed ends 358 and 360 of embedded metal studs 344 and 346 areimbedded in concrete 370 that is applied to outer face 362.

The spacing between each of embedded metal studs 344 and 346 is at least25 and in some cases at least 30 cm and can be up to 110, in some casesup to 100, in other cases up to 75, and in some instances up to 60 cmmeasured from a midpoint of exposed end 358 to a midpoint of exposed end360. The spacing between embedded metal studs 344 and 346 can be anydistance or range between any of the distances recited above.

In an embodiment of the invention, one-sided wall panel 340 includesexpanded polymer body 342 (central body), embedded metal studs 344 and346 (reinforcing embedded bars), which include flanges 311, corneredends 312, utility holes 346 located in an exposed portion of embeddedmetal studs 344 and 346, expansion holes 313 in an embedded portion ofembedded metal studs 344 and 346, and embedded ends 344 and 346, whichdo not touch inner face 350.

In an embodiment of the invention, inner face 350 can have a corrugatedsurface, which can be molded in or cut in, which enhances air flowbetween inner face 350 and any surface attached thereto.

Expansion holes 313 are useful in that as expanded polymer body 342 ismolded, the polymer matrix expands through expansion holes 313 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded metal studs 344 and 346 by way of fusion in the expandingpolymer. In an embodiment of the invention, expansion holes 313 can havea flanged and in many cases a rolled flange surface to provided addstrength to the embedded metal studs.

Openings 348 can have various cross-sectional shapes, non-limitingexamples being round, oval, elliptical, square, rectangular, triangular,hexagonal or octagonal. The cross-sectional size of openings 348 can beuniform or they can vary independently of each other with regard to sizeand location relative to outer face 362 and inner face 350. The spacingbetween each opening 348 can be at least 1 and in some cases at least 3cm and can be up to 110, in some cases up to 100, in other cases up to75, and in some instances up to 60 cm measured from a midpoint of oneopening 348 to an adjacent opening 348. The spacing between openings 348can independently be any distance or range between any of the distancesrecited above.

The cross-sectional area of openings 348 can also vary independently onefrom another or they can be uniform. The cross-sectional area ofopenings 348 is limited by the dimensions of expanded polymer form 342,as openings 348 will fit within the dimensions of expanded polymer form342. The cross-sectional area of openings 348 can independently be atleast 1, in some cases at least 5, and in other cases at least 9 cm² andcan be up to 130, in some cases up to 100, in other cases up to 75 cm².The cross-sectional area of openings 348 can independently be any valueor range between any of the values recited above.

Reinforced body 341 has a finite length and has a male terminal end 371that includes forward edge 372 and a receiving end 376 which includesrecessed section 376, which is adapted to receive forward edge 372.Typically, lengths of one-sided wall panel 340 are interconnected byinserting a forward edge 372 from a first one-sided wall panel 340 intoa recessed section 378 of a second one-sided wall panel. In this manner,a larger wall or ceiling section containing any number of one-sided wallpanels can be assembled and/or arrayed. The width of one-sided wallpanel 340, measured as the distance from protruding edge 380 to trailingedge 374 can typically be at least 20, in some cases at least 30, and inother cases at least 35 cm and can be up to 150, in some cases up to135, and in other cases up to 125 cm. The width of one-sided wall panel340 can be any value or can range between any of the values recitedabove.

An example of a one-sided wall panel 340 according to the invention isshown in FIG. 11, where four embedded metal studs 344 and 346 are used.The present LWC composition is poured, finished and set to form aconcrete layer 370 that encases exposed ends 358 and 360 of embeddedmetal studs 344 and 346.

The embedded ends 350 and 356 of embedded metal studs 344 and 346 areavailable as attachment points for a finish surface such as wood, rigidplastics, wood paneling, concrete panels, cement panels, drywall,sheetrock, particle board, rigid plastic panels, or any other suitablematerial having decorating and/or structural functions or otherconstruction substrates sheetrock 375 as shown in FIG. 11). In aparticular embodiment of the invention, the lightweight gypsum basedproduct described below is used as drywall or sheetrock 375. Theattachment is typically accomplished through the use of screws.

An embodiment of the invention is shown in FIG. 12. In this embodiment,reinforcement mesh 371 is attached to exposed ends 358 and 360 ofembedded metal studs 344 and 346. Reinforcement mesh 371 can be made ofany suitable material, non-limiting examples being fiberglass, metalssuch as steel, stainless steel and aluminum, plastics, synthetic fibersand combinations thereof. Desirably, after reinforcement mesh 371 isattached to exposed ends 358 and 360, concrete layer 370 is poured,finished and set so as to encase reinforcement mesh 371 and exposed ends358 and 360. In this embodiment, reinforcement mesh 371 increases thestrength of concrete layer 370 as well as increasing the strength of theattachment of concrete layer 370 to reinforced body 341.

In an embodiment of the invention, one-sided wall panel 340 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting one-sided wall panel 340 generallyperpendicular to the flat surface. This is often referred to as “tiltinga wall” in the art and in this embodiment of the invention, one-sidedwall panel 340 is referred to as a “tilt-up wall.”

An embodiment of the invention relates to a second tilt up insulatedpanel that is adapted for use as a wall or ceiling panel. As shown inFIGS. 15-18, two-sided wall panel 440 includes a reinforced body 441that includes expanded polymer form 442 (central body) and embeddedmetal studs 444 and 446 (embedded reinforcing bars). Expanded polymerform 442 can include openings 448 that traverse all or part of thelength of expanded polymer form 442. The embedded metal studs 444 and446 have a first exposed end 452 and second exposed end 456 respectivelythat extend from first face 462 of expanded polymer form 442. Theembedded metal studs 444 and 446 also have second exposed ends 458 and460 respectively that extend from second face 450 of expanded polymerform 442.

Expanded polymer form 442 can have a thickness, measured as the distancefrom second face 450 to first face 462 similar in dimensions to thatdescribed above regarding expanded polymer form 342.

The exposed ends can extend at least 1, in some cases at least 2, and inother cases at least 3 cm away either face 450 or face 462 of expandedpolymer form 442. Also, The exposed ends can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from either face ofexpanded polymer form 442. The exposed ends can extend any of thedistances or can range between any of the distances recited above fromeither face of expanded polymer form 442.

In an embodiment of the invention, exposed ends 452, 456, 458, and 460are imbedded in first concrete layer 469 and second concrete layer 470that are applied to faces 450 and 462.

The spacing between each of embedded metal studs 444 and 446 can be asdescribed regarding embedded metal studs 344 and 346.

In an embodiment of the invention, two-sided wall panel 440 includesexpanded polymer body 442 (central body), embedded metal studs 444 and446 (reinforcing embedded bars), which cornered ends 412, utility holes446 located in an exposed portion of embedded metal studs 444 and 446,and expansion holes 413 in an embedded portion of embedded metal studs444 and 446.

Expansion holes 413 are useful in that as expanded polymer body 442 ismolded, the polymer matrix expands through expansion holes 413 and theexpanding polymer fuses. This allows the polymer matrix to encase andhold embedded metal studs 444 and 446 by way of fusion in the expandingpolymer. In an embodiment of the invention, expansion holes 413 can havea flanged and in many cases a rolled flange surface to provided addedstrength to the embedded metal studs.

Openings 448 can have various cross-sectional shapes, and similarspacing and cross-sectional area as described regarding openings 348 inexpanded polymer body 342.

Reinforced body 441 has a finite length and has a male terminal end 471that includes forward edge 472 and a receiving end 476 which includesrecessed section 478, which is adapted to receive forward edge 472.Typically, lengths of two-sided wall panel 440 are interconnected byinserting a forward edge 472 from a first two-sided wall panel 440 intoa recessed section 478 of a second two-sided wall panel. In this manner,a larger wall or ceiling section containing any number of two-sided wallpanels can be assembled and/or arrayed. The width of one-sided wallpanel 440, measured as the distance from forward edge 472 to recessedsection 478 can typically be at least 20, in some cases at least 30, andin other cases at least 35 cm and can be up to 150, in some cases up to135, and in other cases up to 125 cm. The width of two-sided wall panel440 can be any value or can range between any of the values recitedabove.

An example of a two-sided wall panel 440 according to the invention isshown in FIG. 15, where four embedded metal studs 444 and 446 are used.The present LWC composition is poured, finished and set to form concretelayers 469 and 470 that encases exposed ends 452, 456, 458, and 460 ofthe embedded metal studs.

Alternatively, as shown in FIG. 17, two-sided wall panel 439 includesvariations of two-sided wall panel 440. In two-sided wall panel 439 one(or alternatively both, which is not shown) of exposed ends 452 and 456(and alternatively also 458 and 460) are available as attachment pointsfor a finish surface 475 such as wood, rigid plastics, wood paneling,concrete panels, cement panels, drywall, sheetrock, particle board,rigid plastic panels, or any other suitable material having decoratingand/or structural functions or other construction substrates. Thedrywall or sheetrock can include the lightweight gypsum based productdescribed below. The attachment is typically accomplished through theuse of screws. In this embodiment, the space 476 defined by the finishedsurface, the exposed ends 444 and 446 and the expanded polymer body 442can be used to run utilities, insulation and anchors for interiorfinishes as described above.

In this alternative embodiment, reinforcement mesh 471 is attached toexposed ends 458 and 460 of embedded metal studs 444 and 446.Reinforcement mesh 471 can be made of any suitable material,non-limiting examples being fiberglass, metals such as steel, stainlesssteel and aluminum, plastics, synthetic fibers and combinations thereof.Desirably, after reinforcement mesh 471 is attached to exposed ends 458and 460, concrete layer 470 is is poured, finished and set so as toencase reinforcement mesh 471 and exposed ends 458 and 460. In thisembodiment, reinforcement mesh 471 increases the strength of concretelayer 470 as well as increasing the strength of the attachment ofconcrete layer 470 to reinforced body 441.

In an embodiment of the invention, two-sided wall panel 440 is assembledon a flat surface and a first end is lifted while a second end remainsstationary resulting in orienting two-sided wall panel 440 generallyperpendicular to the flat surface, i.e., “tilting a wall” as describedabove.

The present invention also provides floor units and floor systems thatinclude composite floor panels containing the present lightweightconcrete composition. The floor panels generally include a central body,substantially parallelepipedic in shape, containing an expanded polymermatrix, having opposite faces, a top surface, and an opposing bottomsurface; and two or more embedded floor joists longitudinally extendingacross the central body between the opposite faces, having a first endembedded in the expanded polymer matrix, having a first transversemember extending from the first end generally contacting or extendingabove the top surface, a second end extending away from the bottomsurface of the central body having a second transverse member extendingfrom the second end, and one or more expansion holes located in theembedded joists between the first end of the embedded joists and thebottom surface of the central body. The central body contains a polymermatrix as described above that expands through the expansion holes. Theembedded joists include one or more utility holes located in theembedded joists between the bottom surface of the central body and thesecond end of the embedded joists and the space defined by the bottomsurface of the central body and the second ends of the reinforcingembedded joists is adapted for accomodating utility lines. A concretelayer containing the present lightweight cementitious composition coversat least a portion of the top surface and/or bottom surface. Thecomposite floor panel is positioned generally perpendicular to astructural wall and/or foundation.

As shown in FIG. 19, floor unit 90 includes expandable polymer panel 92(central body) and embedded metal joists 94 and 96 (reinforcing embeddedbars). Expandable polymer panel 92 includes openings 98 that traverseall or part of the length of expanded polymer panel 92. The embeddedmetal joists 94 and 96 have embedded ends 104 and 106 respectively thatare in contact with top surface 102 of expanded polymer panel 92. Theembedded metal joists 94 and 96 also have exposed ends 108 and 110respectively that extend from bottom surface 100 of expanded polymerpanel 92.

Embedded metal joists 94 and 96 include first transverse members 124 and126 respectively extending from embedded ends 104 and 106 respectively,which are generally in contact with top surface 102 and exposed ends 108and 110 include second transverse members 128 and 129 respectively,which extend from exposed ends 108 and 110 respectively. The spacedefined by bottom surface 100 of expanded polymer panel 92 and theexposed ends 108 and 110 and second transverse members 128 and 129 ofembedded metal joists 94 and 96 can be oriented to accept ductworkplaced between embedded metal joists 94 and 96 adjacent bottom surface100.

Expanded polymer panel 92 can have a thickness, measured as the distancefrom top surface 102 to bottom surface 100 of at least 2, in some casesat least 2.5, and in other cases at least 3 cm and can be up to 50, insome cases up to 40, in other cases up to 30, in some instances up to25, in other instances up to 20, in some situations up to 15 and inother situations up to 10 cm from top surface 102 of expanded polymerpanel 92. The thickness of panel 92 can be any distances or can rangebetween any of the distances recited above.

Exposed ends 108 and 110 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away from bottom surface 100 ofexpanded polymer panel 92. Also, Exposed ends 108 and 110 can extend upto 60, in some cases up to 40, and in other cases up to 20 cm away frombottom surface 100 of expanded polymer panel 92. Exposed ends 108 and110 can extend any of the distances or can range between any of thedistances recited above from bottom surface 100.

In an embodiment of the invention, embedded metal joists 94 and 96 havea cross-sectional shape that includes embedding lengths 114 and 116,embedded ends 104 and 106, and exposed ends 108 and 110. The orientationof embedded metal joists 94 and 96 is referenced by the direction ofopen ends 118 and 120. In an embodiment of the invention, open ends 118and 120 are oriented toward each other. In this embodiment, floor unit90 is adapted to accept ductwork. As a non-limiting example, a HVAC ductcan be installed along the length of embedded metal joists 94 and 96.

As used herein, the term “ductwork” refers to any tube, pipe, channel orother enclosure through which air can flow from a source to a receivingspace; non-limiting examples being air flowing from heating and/orair-conditioning equipment to a room, make-up air flowing from a room toheating and/or air-conditioning equipment, fresh air flowing to anenclosed space, and/or waste air flowing from an enclosed space to alocation outside of the enclosed space. In some embodiments, ductworkincludes generally rectangular metal tubes that are located below andextend generally adjacent to a floor.

The spacing between each of embedded metal joists 94 and 96 can be asdescribed regarding embedded metal studs 344 and 346.

Openings 98 can have various cross-sectional shapes, and similar spacingand cross-sectional area as described regarding openings 348 in expandedpolymer body 342.

As shown in FIG. 19, expanded polymer panel 92 can extend for a distancewith alternating embedded metal joists 94 and 96 placed therein. Thelength of floor unit 90 can be any length that allows for safe handlingand minimal damage to floor unit 90. The length of floor unit 90 cantypically be at least 1, in some cases at least 1.5, and in other casesat least 2 m and can be up to 25, in some cases up to 20, in other casesup to 15, in some instances up to 10 and in other instances up to 5 m.The length of floor unit 90 can be any value or can range between any ofthe values recited above. In some embodiments, an end of floor unit 90can be terminated with an embedded metal joist.

As shown in FIG. 19, expanded polymer panel 92 has a finite length andhas a male terminal end 91 that includes forward edge 93 and trailingedge 95 and a receiving end 97 which includes recessed section 99 andextended section 101, which is adapted to receive forward edge 93, andtrailing edge 95. Typically, lengths of floor units 90 areinterconnected by inserting a forward edge 93 from a first floor unit 90into a recessed section 99 from a second floor unit 90. In this manner,a larger floor section containing any number of floor units can beassembled and/or arrayed.

The width of floor unit 90 can be any width that allows for safehandling and minimal damage to floor unit 90. The width of floor unit 90is determined by the length of embedded metal joists 94 and 96. Thewidth of floor unit 90 can be at least 1 and in some cases at least 1.5m and can be up to 3 m and in some cases up to 2.5 m. In some instances,in order to add stability to floor unit 90, reinforcing cross-members(not shown) can be attached to embedded metal joists 94 and 96. Thewidth of floor unit 90 can be any value or can range between any of thevalues recited above.

Floor unit 90 is typically part of an overall floor system that includesa plurality of the composite floor panels described herein, where themale ends include a tongue edge and the female ends include a groovearrayed such that a tongue and/or groove of each panel is in sufficientcontact with a corresponding tongue and/or groove of another panel toform a plane. A concrete layer that contains the present lightweightconcrete composition covers at least a portion of a surface of the floorsystem. The established plane extends laterally from a foundation and/ora structural wall.

In the present floor system, ductwork can be attached to the reinforcingmetal bars of at least one composite floor panel.

Additionally, a flooring material can be attached to one or more of thefirst transverse members of the composite floor panels. Any suitableflooring material can be used in the invention. Suitable flooringmaterials are materials that can be attached to the transverse membersand cover at least a portion of the expanded polymer panel. Suitableflooring materials include, but are not limited to plywood, wood planks,tongue and grooved wood floor sections, sheet metal, sheets ofstructural plastics, stone, ceramic, cement, concrete, and combinationsthereof.

An embodiment of the invention relates to a floor or tilt up insulatedpanel that is adapted to act as a lightweight concrete I-beam form. Asshown in FIG. 20, I-beam panel 140 includes expanded polymer form 142(central body) and embedded metal studs 144 and 146 (embeddedreinforcing bars). Expanded polymer form 142 includes openings 148 thattraverse all or part of the length of expanded polymer form 142. Theembedded metal studs 144 and 146 have embedded ends 152 and 156respectively that are in contact with inner face 150 of expanded polymerform 142. The embedded metal studs 144 and 146 also have exposed ends158 and 160 respectively that extend from outer face 162 of expandedpolymer form 142.

Expanded polymer form 142 can have a thickness, measured as the distancefrom inner face 150 to outer face 162 similar in dimensions to thatdescribed above regarding expanded polymer panel 92.

Exposed ends 158 and 160 extend at least 1, in some cases at least 2,and in other cases at least 3 cm away outer face 162 of expanded polymerform 142. Also, Exposed ends 158 and 160 can extend up to 60, in somecases up to 40, and in other cases up to 20 cm away from outer face 162of expanded polymer form 142. Exposed ends 158 and 160 can extend any ofthe distances or can range between any of the distances recited abovefrom outer face 100.

In an embodiment of the invention, embedded metal studs 144 and 146 havea cross-sectional shape that includes embedding lengths 164 and 166,embedded ends 152 and 156, and exposed ends 158 and 160. The orientationof embedded metal studs 144 and 146 is referenced by the direction ofopen ends 168 and 170. In an embodiment of the invention, open ends 168and 170 are oriented toward each other. In this embodiment, I-beam panel140 is adapted to be imbedded in lightweight concrete that can beapplied to outer face 162.

The spacing between each of embedded metal studs 144 and 146 can be asdescribed regarding embedded metal studs 344 and 346.

Openings 148 can have various cross-sectional shapes, and similarspacing and cross-sectional area as described regarding openings 348 inexpanded polymer body 342.

As shown in FIG. 20, expanded polymer panel 140 has a finite length andhas a male terminal end 170 that includes forward edge 172 and trailingedge 174 and a receiving end 176 which includes recessed section 178,which is adapted to receive forward edge 172, and protruding edge 180.Typically, lengths of I-beam panels 140 are interconnected by insertinga forward edge 172 from a first I-beam panel 140 into a recessed section178 of a second I-beam panel. In this manner, a larger roof, ceiling,floor or wall section containing any number of I-beam panels can beassembled and/or arrayed. The width of I-beam panel 140, measured as thedistance from protruding edge 180 to trailing edge 174 can typically beat least 20, in some cases at least 30, and in other cases at least 35cm and can be up to 150, in some cases up to 135, and in other cases upto 125 cm. The width of I-beam panel 140 can be any value or can rangebetween any of the values recited above.

I-beam panel 140 includes I-beam channel 182. The present I-beam panelis advantageous when compared to prior art systems in that theconnection between adjacent panels in the prior art is provided alongthe thin section of expanded polymer below I-beam channel 182. Theresulting thin edge is prone to damage and/or breakage during shipmentand handling. The I-beam panel of the present invention eliminates thisproblem by molding in the I-beam channel, eliminating the exposure of athin edge section to potential damage.

In an embodiment of the invention, rebar or other concrete reinforcingrods can be placed in I-beam channel 182 in order to strengthen andreinforce a lightweight concrete I-beam formed within I-beam channel182.

In another embodiment of the invention shown in FIG. 21, instead ofI-beam channel 182, I-beam panel 141 includes channel 183. Channel 183is adapted to accept round ductwork or other mechanical and utilityparts and devices and/or can be filled with lightweight concrete asdescribed above.

An example of an I-beam system 200 according to the invention is shownin FIG. 22, where four I-beam panels 140 are connected by inserting aforward edge 172 from a first I-beam panel 140 into a recessed section178 of a second I-beam panel. Lightweight concrete is poured, finishedand set to form a lightweight concrete layer 202 that includeslightweight concrete I-beams 204, which are formed in I-beam channels182. The embodiment shown in FIG. 22 is an alternating embodiment, wherethe direction of I-beam channel 182 of each I-beam panel 140 alternatelyfaces toward lightweight concrete layer 202 and includes lightweightconcrete I-beam 204 or faces away from lightweight concrete layer 202and I-beam channel 182 does not contain concrete. In an embodiment ofthe invention, the facing away I-beam panel can be I-beam panel 141.Alternatively, every I-beam panel 140 could face lightweight concretelayer 202 and include lightweight concrete I-beam 204.

In the embodiment shown, exposed ends 158 and 160 are either embedded inlightweight concrete layer 202 or are exposed. The exposed ends 158 and160 are available as attachment points for a finish surface 210, whichcan include wood, rigid plastics, wood paneling, concrete panels, cementpanels, drywall, sheetrock, particle board, rigid plastic panels,lightweight concrete construction articles described herein, or anyother suitable material having decorating and/or structural functions orother construction substrates 210. The attachment is typicallyaccomplished through the use of screws, nails, adhesive or otherfasteners known in the art.

In an embodiment of the invention, I-beam system 200 is assembled on aflat surface and a first end is lifted while a second end remainsstationary resulting in orienting I-beam system 200 generallyperpendicular to the flat surface and erected by “tilting a wall” asdescribed above.

In another embodiment of the invention, I-beam system 200 can be used asa roof on a structure or a floor in a structure.

Generally, the floor system forms a plane that extends laterally from afoundation and/or a structural wall.

FIGS. 23 and 24 show floor systems 140 and 141 respectively. Floorsystem 140 is established by contacting forward edge 93 with recessedsection 99 to form a continuous floor 142. Like features of theindividual floor panels are labeled as indicated above. As describedabove, various shaped types of ductwork can be secured in the spacedefined by bottom surface 100 of expanded polymer panel 92 and theexposed ends 108 and 110 and second transverse members 128 and 129 ofembedded metal joists 94 and 96. As non-limiting examples, rectangularventilation duct 147 is shown in FIG. 23 and circular air duct 148 isshown in FIG. 24.

Embodiments of the present invention provide a composite building panelthat includes a central body, substantially parallelepipedic in shape,containing an expanded polymer matrix as described above, havingopposite faces, a top surface, and an opposing bottom surface; at leastone embedded framing stud longitudinally extending across the centralbody between the opposite faces, having a first end embedded in theexpanded polymer matrix, a second end extending away from the bottomsurface of the central body, and one or more expansion holes located inthe embedded stud between the first end of the embedded stud and thebottom surface of the central body, where the central body contains apolymer matrix that expands through the expansion holes; and alightweight concrete layer covers at least a portion of the top surfaceand/or bottom surface.

The embodiment of the invention shown in FIG. 24 shows an example ofusing combinations of the composite panels described herein andcombining features of the various panels. This embodiment combinesI-beam panel 140 and floor panel 92 (shown as 92 and 92A). In thisembodiment, receiving end 176 of I-beam panel 140 accepts forward edge93 of floor panel 92 and recessed section 99 of floor panel 92A acceptsforward edge 172 of I-beam panel 140 to provide tongue and grooveconnections to establish continuous floor system 141. In thisembodiment, circular ductwork 148 is installed along bottom surface 100of floor panel 92 between embedded metal joists 94 and 96. In thisembodiment, the flooring material is the present lightweight concretecomposition as layer 145, which covers top surface 102 of floor panels92 and 92A and outer face 162 of I-beam panel 140. I-beam channel 182extends from and is open to outer face 162 and is filled withlightweight concrete and the thickness of concrete layer 145 issufficient to encase exposed ends 158 and 160 of I-beam panel 140. Thecombination shown in this embodiment provides an insulated concretefloor system where utilities can be run under an insulation layer.

As shown in the embodiment of FIG. 23, a layer of the presentlightweight concrete composition 149, with a grooved exposed surface,covers floor units 90. In an alternative embodiment (not shown) aplywood, plastic, particle board or other suitable sub-floor can beattached to first transverse members 124 and 126 and the lightweightconcrete composition layer 149 applied thereto.

As shown in FIG. 25, an end of embedded metal joists 94 and 96 areseated in and attached to a joist rim 122 and a second joist rim isattached to the other end of embedded metal joists 94 and 96. Alightweight concrete layer 149, as a floor, can be applied overtransverse members 124 and/or 126.

Referring to FIG. 25, embedded metal joists 94 and 96 have utility holes127 spaced along their length. Utility holes 127 are useful foraccommodating wiring for electricity, telephone, cable television,speakers, and other electronic devices. Utility holes 127 can havevarious cross-sectional shapes, non-limiting examples being round, oval,elliptical, square, rectangular, triangular, hexagonal or octagonal. Thecross-sectional area of Utility holes 127 can also vary independentlyone from another or they can be uniform. The cross-sectional area ofutility holes 127 is limited by the dimensions of embedded metal joists94 and 96, as utility holes 127 will fit within their dimensions and notsignificantly detract from their structural integrity and strength. Thecross-sectional area of utility holes 127 can independently be at least1, in some cases at least 2, and in other cases at least 5 cm² and canbe up to 30, in some cases up to 25, in other cases up to 20 cm². Thecross-sectional area of utility holes 127 can independently be any valueor range between any of the values recited above.

Expansion holes 113, as mentioned above are useful in that as expandedpolymer body 92 is molded, the polymer matrix expands through expansionholes 113 and the expanding polymer fuses. This allows the polymermatrix to encase and hold embedded studs 94 and 96 by way of the fusionin the expanding polymer. In an embodiment of the invention, expansionholes 113 can have a flanged and in many cases a rolled flange surfaceto provided added strength to the embedded metal studs.

In an embodiment of the invention, the floor system can be placed on afoundation. However, because foundations are rarely perfectly level, alevel track can be attached to the foundation prior to placement of thefloor system. The level track includes a top surface having a length andtwo side rails extending from opposing edges of the top surface, wherethe width of the top surface is greater than a width of the foundationand the length of the top surface is generally about the same as thelength of the foundation. The level track is generally attached to thefoundation by placing the level track over the foundation with the siderails generally contacting the sides of the foundation, situating thetop surface such that it conforms to level and permanently attaching thelevel track to the foundation. A rim joist can be used to aid inattaching the top surface to an end of the plurality of composite floorpanels.

More particularly, a level track 128 can be attached to foundation 130prior to placement of the floor system (see FIGS. 25 and 26). Leveltrack 128 can be placed on foundation 128 and leveled. The level is madepermanent by fastening level track 128 to foundation 130 by usingfasteners 131 (nails shown, although screws or other suitable devicescan be used) via fastening holes 132. Screws 133 can also be used toattach level track 128 to foundation 130 via screw holes 135. Some ofscrew holes 135 can be used in conjunction with screws 133 to attach abottom lip of joist rim 122 to level track 128. Screws 133 can alsomaintain the level position of level track 128 until a more permanentpositioning is achieved. Alternatively or additionally mortar can beapplied via mortar holes 134 to fill the space between level track 128and the top of foundation 130. After level track 128 has been attachedand/or the mortar has sufficiently set, the flooring system can befastened to the foundation.

Level track 128 includes side rails 137, which are adapted to extendover a portion of foundation 130. The width of level track 128 is thetransverse distance of a top portion of level track 128 from one siderail 137 to the other. The width of level track 128 is typicallyslightly larger than the width of foundation 130. The width of leveltrack 128 can be at least 10 cm, in some cases at least 15 cm, in othercases at least 20 cm and in some instances at least 21 cm. Also, thewidth of level track 128 can be up to 40 cm, in some cases up to 35 cm,and in other cases up to 30 cm. The width of level track 128 can be anyvalue or range between any of the values recited above.

The length of side rail 137 is the distance it extends from a topportion of level track 128 and is sufficient in length to allow forproper leveling of level track 128 and attachment to foundation 130 viafasteners 131 and fastening holes 132. The length of side rail 137 canbe at least 4 cm, in some cases at least 5 cm, and in other cases atleast 7 cm. Also, the length of side rail 137 can be up to 20 cm, insome cases up to 15 cm, and in other cases up to 12 cm. The length ofside rail 137 can be any value or range between any of the valuesrecited above.

A wall system 50 can be attached to or set on lightweight concrete layer149 as shown in FIG. 25. In wall system 50, a bottom end of metal studs14 and 16, partially embedded in polymer body 14 are seated in andattached to a bottom track 44 and a top slip track (not shown). Thisconfiguration leads to the formation of bottom channel 52.

In an embodiment of the invention, the LWC composition is formed, setand/or hardened in the form of a construction panel, without the use ofa pre-formed building panel as described above. In this embodiment, theconstruction panel can be adapted for use in a floor, wall, ceiling, orroof.

Additionally, the LWC compositions of the invention can be used as astucco or as a plaster, being applied by any means well known to thoseof ordinary skill in those trades; as a wall board, of the sandwich typeof construction wherein the hardened material is sandwiched by suitablystrong paper or other construction material; as pavers for sidewalks,driveways and the like; as a pour material for sidewalks, driveways andthe like; as a monolithic pour material for floors of buildings; aschimney stacks or smoke stacks; as bricks; as roof pavers; as monolithicpour material for radiant heat floor systems; as blocks for landscaperetaining walls; as pre-stressed concrete wall systems; as tilt-up wallsystems, i.e. where a wall component is poured on site and then tiltedup when hardened; and as mason's mortar.

In an embodiment of the invention, the concrete compositions accordingto the invention are formed, set and/or hardened in the form of aconcrete masonry unit. As used herein, the term “concrete masonry unit”refers to a hollow or solid concrete article including, but not limitedto scored, split face, ribbed, fluted, ground face, slumped and pavingstone varieties. Embodiments of the invention provide walls thatinclude, at least in part, concrete masonry units made according to theinvention.

In an embodiment of the invention, the molded construction articles andmaterials and concrete masonry units described above are capable ofreceiving and holding penetrating fasteners, non-limiting examples ofsuch include nails, screws, staples and the like. This can be beneficialin that surface coverings can be attached directly to the moldedconstruction articles and materials and concrete masonry units moldedconstruction articles and materials and concrete masonry units.

In an embodiment of the invention, a standard 2½ inch drywall screw canbe screwed into a poured and set surface containing the present lightweight concrete composition, to a depth of 1½ inches, and is not removedwhen a force of at least 500, in some cases at least 600 and in othercases at least 700 and up to 800 pounds of force is appliedperpendicular to the surface screwed into for one, in some cases fiveand in other cases ten minutes.

Embodiments of the present invention provide lightweight structuralunits such as gypsum wallboard and the like. These units include a coreof cementitious material as described above, covered at least on both ofits major surfaces by cover or face papers which are adhered to thecured cementitious core. While the product to be made can be describedas a gypsum wallboard in which the base cementitious material is someform of gypsum composition or combinations of gypsum compositions, itwill be understood that for different applications, other forms ofcementitious material such as plaster of Paris, stucco, cements of allkinds may be used to make other products and fall within the scope ofthe present invention.

As used herein, the term “gypsum” refers to the mineral gypsum as foundin nature is primarily calcium sulfate dihydrate (CaSO₄.2H₂O) and“gypsum compositions” refer to compositions and/or mixtures that containgypsum. To make gypsum wallboard, the mineral is ground and calcined sothat it is primarily the hemihydrate of calcium sulfate (CaSO₄.½H₂O) anddenoted as hemihydrate, stucco or calcined gypsum. If dehydration iscomplete, calcium sulfate (CaSO₄.).

Embodiments of the invention provide for making a lightweight core for astructural unit includes the following combinations of materials:

-   -   (1) a base gypsum composition that includes calcined gypsum;    -   (2) polymer particles having an average particle size of from        0.2 mm to 8.0 mm and a bulk density of from 0.03 g/cc to 0.64        g/cc as described above;    -   (3) optionally a surfactant,    -   (4) optionally a frothing agent suitable for use with latex;    -   (5) optionally a film forming component, such as a latex;    -   (6) optionally a starch composition, and    -   (7) optionally water, plus other additives as may be desired.

The slurry or mixture can be prepared by adding to a suitable vessel apart of the water, one or more surfactants, and a frothing agent, whichunder agitation forms a froth. After allowing for appropriate air to beentrained, the latex and starch can be added. During continuedagitation, the gypsum is added slowly to prevent lumping or clumping,and then the balance of the predetermined amount of water is added. Tothis the polymer particles are added with stirring or agitationcontinued to obtain a smooth homogeneous mixture. When it serves anadvantageous purpose, the order of addition can be varied.

In an embodiment of the invention, the polymer particles can be added tothe gypsum based material at from about 0.1 to up to about 3% by weightof the gypsum, in some cases from about 0.5 to about 3 weight percent,from about 10 to about 60 percent by volume of the gypsum basedmaterial, or at the levels defined above.

The latex can be used at from about 0.1 to about 5.0 percent by weightof gypsum and in some cases from 1 to 3 weight percent.

In an embodiment of the invention, the latex contains a styrenebutadiene copolymer, a vinyl acetate homopolymer or copolymer, anon-limiting example being an ethylene vinyl acetate copolymer, orcombinations thereof.

The surfactant and/or frothing agent, when used as a single or combinedadditive, can be used at from about 0.075% to about 0.3% by weight ofgypsum, in some cases about 0.1 to 0.2 weight percent. In particularembodiments, magnesium lauryl sulfate is used.

The starch can be used at from about 0.5 to about 3.0% by weight ofgypsum, and in some cases at about 1 to about 2 weight percent.

Gypsum, limestone and/or dolomite can provide the balance of theformulation.

Advantageously, the polymer particles not only lighten the weight of thewallboard, but add insulating value and in reducing the amount of gypsumthey reduce the water requirement in the formulation. Thus an advantageto the present invention is that the gypsum mixture or slurry requiresvery little or no water in excess of that required for proper hydration.Further, the total water content in the gypsum based material can be aslow as practicable, on the order of about 50 to 60% by weight ofhemihydrate, keeping in mind that it is desirable to use only as muchexcess of water over that required to react with the cementitiouscompound as is necessary to provide the desired homogenous flowablemixture which may by readily placed into a mold or other means formaking lightweight cementitious cores for wallboard.

The prepuff or polymer particle density, diameter and volume can bevaried to provide targeted and/or otherwise desirable properties to thegypsum composition. This permits the engineering of specificcharacteristics into sheetrock, wallboard or other products made fromthe present lightweight gypsum composition, non-limiting examples beingfire resistance, insulation value, shear resistance, finished boardweight, and/or fastener holding and tear-out strength.

An advantage to the present invention is the more uniform size anddistribution of the polymer particles within the wallboard or gypsummaterial than prior art attempts at including expanded particles in thewallboard and/or compositions. Further, the presence of the polymerparticles provides added strength as well as flexibility to thewallboard. In the final product, this shows up as an increase incompressive strength as well as flexural strength.

In an embodiment of the invention, when wallboard containing theabove-described gypsum composition is exposed to extreme heat and/orflames, a honeycomb structure results which can maintain much of thestrength of the wall board. This can be advantageous in increasing thelength of time until failure, which aids in evacuating structures madeusing such materials.

In an embodiment of the invention, a standard 1¼″ inch drywall screw canbe screwed into the present light weight wallboard or gypsum material,to a depth of ½ inches, and is not removed when a force of at least 500,in some cases at least 600 and in other cases at least 700 and up to 800pounds of force is applied perpendicular to the surface screwed into forone, in some cases five and in other cases ten minutes.

In an embodiment of the invention, wallboard containing theabove-described gypsum composition has a minimum compressive strength ofat least 300 psi (21.1 kgf/cm²), in some cases at least 400 psi (28.1kgf/cm²), in other cases at least 500 psi (35.2 kgf/cm²), in someinstances at least 600 psi (42.2 kgf/cm²), and in other instances atleast 700 psi (49.2 kgf/cm²). Compressive strengths are determinedaccording to ASTM C39.

The present invention is also directed to buildings that include the LWCcompositions according to the invention.

The present invention also provides a method of making an optimizedlightweight concrete article that includes:

-   -   identifying the desired density and strength properties of a set        lightweight concrete composition;    -   determining the type, size and density of polymer beads to be        expanded for use in the light weight concrete composition;    -   determining the size and density the polymer beads are to be        expanded to;    -   expanding the polymer beads to form expanded polymer beads;    -   dispersing the expanded polymer beads in a cementitious mixture        to form the light weight concrete composition; and    -   allowing the light weight concrete composition to set in a        desired form.

The desired density and strength properties of the set and/or hardenedLWC composition are determined based on the intended application.

In an embodiment of the invention, the type, size and density of polymerbeads to be expanded and the size and density the polymer beads are tobe expanded to can be determined based on empirical and/or publisheddata.

In another embodiment of the invention finite element analysis can beused to determine the type, size and density of polymer beads to beexpanded and the size and density the polymer beads are to be expandedto.

The resulting lightweight concrete composition is allowed to set and/orharden to provide LWC articles and concrete masonry units as describedabove.

The present invention will further be described by reference to thefollowing examples. The following examples are merely illustrative ofthe invention and are not intended to be limiting. Unless otherwiseindicated, all percentages are by weight and Portland cement is usedunless otherwise specified.

EXAMPLES

Unless otherwise indicated, the following materials were utilized:

-   -   Type III Portland Cement (CEMEX, S.A. de C.V., MONTERREY,        MEXICO).    -   Mason Sand (165 pcf bulk density/2.64 specific gravity)    -   Potable Water—ambient temperature (˜70° F./21° C.)    -   Expandable Polystyrene—M97BC, F271C, F271M, F271T (NOVA        Chemicals Inc., Pittsburgh, Pa.)    -   EPS Resin—1037C (NOVA Chemicals, Inc.)    -   ½ inch Expanded Slate (Carolina Stalite Company, Salisbury,        N.C.—89.5 pcf bulk density/1.43 specific gravity)

Unless otherwise indicated, all compositions were prepared underlaboratory conditions using a model 42N-5 blender (Charles Ross & SonCompany, Hauppauge, N.Y.) having a 7-ft³ working capacity body with asingle shaft paddle. The mixer was operated at 34 rpm. Conditioning wasperformed in a LH-10 Temperture and Humidity Chamber (manufactured byAssociated Environmental Systems, Ayer, Mass.). Samples were molded in6″×12″ single use plastic cylinder molds with flat caps and were testedin triplicate. Compression testing was performed on a Forney FX250/300Compression Tester (Forney Incorporated, Hermitage, Pa.), whichhydraulically applies a vertical load at a desired rate. All otherperipheral materials (slump cone, tamping rods, etc.) adhered to theapplicable ASTM test method. The following ASTM test methods andprocedures were followed:

-   -   ASTM C470—Standard Specification for Molds for Forming Concrete        Test Cylinders Vertically    -   ASTM C192—Standard Practice for Making and Curing Concrete Test        Specimens in the Laboratory    -   ASTM C330—Standard Specification for Lightweight Aggregates for        Structural Concrete    -   ASTM C511—Standard Specification for Mixing Rooms, Moist        Cabinets, Moist Rooms, and Water Storage Tanks Used in the        Testing of Hydraulic Cements and Concretes    -   ASTM C143—Standard Test Method for Slump of Hydraulic-Cement        Concrete    -   ASTM C1231—Standard Practice for Use of Unbonded Caps in        Determination of Compressive Strength of Hardened Concrete        Cylinders    -   ASTM C39—Standard Test Method for Compressive Strength of        Cylindrical Concrete Specimens

Cylinders were kept capped and at ambient laboratory conditions for 24hours. All cylinders were then aged for an additional 6 days at 23±2°C., 95% relative humidity. The test specimens were then tested.

Example 1

Polystyrene in unexpanded bead form (M97BC—0.65 mm, F271T—0.4 mm, andF271M—0.33 mm) was pre-expanded into EPS foam (prepuff) particles ofvarying densities as shown in the table below.

Prepuff Particle Bead Bulk Bead Mean Size, Density, Mean Size, StandardType μm lb/ft³ μm deviation, μm F271M 330 2.32 902 144 F271M 330 3.10824 80 F271M 330 4.19 725 103 F271T 400 2.40 1027 176 F271T 400 3.691054 137 F271T 400 4.57 851 141 M97BC 650 2.54 1705 704 M97BC 650 3.291474 587 M97BC 650 5.27 1487 584

The data show that the prepuff particle size varies inversely with theexpanded density of the material.

Example 2

Polystyrene in unexpanded bead form (0.65 mm, 0.4 mm, and 0.33 mm) waspre-expanded into prepuff particles with a bulk density of 2 lb/ft³ asshown in the table below. The prepuff particles were formulated into aLWC composition, in a 3.5 cubic foot drum mixer, that included 46.5 wt.% (25.3 vol. %) Portland cement, 16.3 wt. % (26.3 vol. %) water, and 1.2wt. % (26.4 vol. %) prepuff particles. The resulting LWC compositionshad a concrete density of 90 lb/ft². The average compressive strength(determined according to ASTM C39, seven day break test) is shown in thetable below.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi 650 2.00 90 1405 400 2.00 901812 330 2.00 90 1521

The data show that as the mean unexpanded bead size decreases, at aconstant prepuff particle density, that surprisingly higher compressivestrength does not necessarily result from ever decreasing unexpandedbead size as suggested in the prior art. More particularly, the datashow that an optimum unexpanded bead size with respect to compressivestrength at 2.00 pcf exists when loaded to obtain 90 pcf concretedensity. This optimum appears to be between 330 microns and 650 micronsfor this particular formulation.

Example 3

Since the prepuff particle density also impacts the overall concretedensity, changing the EPS density requires a change in the EPS loadinglevel to maintain a constant concrete density. This relationship holdsonly as long as the total amount of prepuff particles is not so large asto compromise the strength of the surrounding concrete matrix. Therelationship between the prepuff particle density and loading levelprovides additional opportunities to optimize concrete strength whilecontrolling the overall concrete density.

Polystyrene in unexpanded bead form (0.65 mm) was pre-expanded intoprepuff particles having varying densities as shown in the table below.The prepuff particles were formulated into LWC compositions containingthe components shown in the table below, in a 3.5 cubic foot drum mixer,and each having a concrete density of 90 lb/ft³.

Sample A Sample B Sample C Prepuff Particle Bulk 1.26 3.29 5.37 Density(lb/ft³) Portland Cement, wt. 46.7 (28.5) 46.2 (22.1) 45.8 (18.9) %(vol. %) Water, wt. % (vol. %) 16.4 (29.8) 16.2 (23) 16.1 (19.7) EPS,wt. % (vol. %) 0.7 (16.8) 1.8 (35.6) 2.6 (44.9) Sand, wt. % (vol. %)36.2 (24.9) 35.8 (19.3) 35.5 (16.5)

The following data table numerically depicts the relationship betweenprepuff density and concrete strength at a constant concrete density of90 lb/ft³.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi Sample A 650 1.26 90 1463Sample B 650 3.29 90 1497 Sample C 650 5.37 90 2157

The data show that as the prepuff particle density increases, thecompressive strength of the LWC composition also increases at constantconcrete density.

Example 4

Polystyrene in unexpanded bead form (0.65 mm) was pre-expanded intoprepuff particles having a bulk density of 1.1 lb/ft³ as shown in thetable below. The prepuff particles were formulated into LWCcompositions, in a 3.5 cubic foot drum mixer, containing the componentsshown in the table below.

Sample D Sample E Sample F Sample G Prepuff Particle Bulk Density(lb/ft³) 1.1 1.1 1.1 1.1 Portland Cement, wt. % (vol. %) 46.4 (22.3)46.8 (21.6) 46.3 (18.9) 46.1 (16.6) Water, wt. % (vol. %) 17 (24.3) 16.4(22.5) 17 (20.6) 17 (18.2) EPS, wt. % (vol. %) 0.6 (33.9) 0.6 (37) 0.9(44) 1.1 (50.8) Sand, wt. % (vol. %) 36 (19.5) 36.2 (18.9) 35.9 (16.5)35.8 (14.5)

The following data table numerically depicts the relationship betweenprepuff density and concrete strength at a constant concrete density of90 lb/ft³.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi Sample D 650 1.1 93.8 1900Sample E 650 1.1 89.6 1252 Sample F 650 1.1 80.9 982 Sample G 650 1.172.4 817

The data show that as prepuff particle loading in the LWC compositionincreases at constant foam particle density, the light weight concretedensity and compressive strength decreases.

Example 5

Polystyrene in unexpanded bead form (0.65 mm) was pre-expanded intoprepuff particles having various densities as shown in the table below.The prepuff particles were formulated into LWC compositions, in a 3.5cubic foot drum mixer, containing the components shown in the tablebelow.

Sample H Sample I Sample J Sample K Prepuff Particle Bulk Density(lb/ft³) 1.1 2.3 3.1 4.2 Portland Cement, wt. % (vol. %) 46.8 (21.6)46.8 (26.8) 46.8 (28.4) 46.8 (29.7) Water, wt. % (vol. %) 16.4 (22.5)16.4 (28) 16.4 (29.6) 16.4 (31) EPS, wt. % (vol. %) 0.6 (37) 0.6 (21.8)0.6 (17.2) 0.6 (13.4) Sand, wt. % (vol. %) 36.2 (18.9) 36.2 (23.4) 36.2(24.8) 36.2 (25.9)

The following table numerically depicts the relationship between prepuffdensity and concrete strength at a constant concrete prepuff loadingbased on the weight of the formulation.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi Sample H 650 1.1 89.6 1252Sample I 650 2.32 109.6 1565 Sample J 650 3.1 111.7 2965 Sample K 6504.2 116.3 3045

The data show that as prepuff particle density in the light weightconcrete composition increases at constant prepuff particle loading (byweight), light weight concrete density and compressive strengthincreases.

Example 6

Polystyrene in unexpanded bead form (0.65 mm) was pre-expanded intoprepuff particles having various densities as shown in the table below.The prepuff particles were formulated into LWC compositions, in a 3.5cubic foot drum mixer, containing the components shown in the tablebelow.

Sample L Sample M Prepuff Particle Bulk Density (lb/ft³) 1.1 3.1Portland Cement, wt. % (vol. %) 46.3 (18.9) 46.2 (21.4) Water, wt. %(vol. %) 17 (20.6) 16.2 (22.3) EPS, wt. % (vol. %) 0.9 (44) 1.8 (37.5)Sand, wt. % (vol. %) 35.9 (16.5) 35.8 (18.7)

The following table numerically depicts the relationship between prepuffdensity and concrete strength at a constant concrete density.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi Sample L 650 1.1 80.9 982Sample M 650 3.1 79.8 1401

The data show that as prepuff particle density in the LWC compositionincreases at constant concrete density, the compressive strength of theLWC increases.

Example 7

Polystyrene in unexpanded bead form (0.65 mm) was pre-expanded intoprepuff particles having various densities as shown in the table below.The prepuff particles were formulated into LWC compositions, in a 3.5cubic foot drum mixer, containing the components shown in the tablebelow.

Sample N Sample O Prepuff Particle Bulk Density (lb/ft³)  3.9  5.2Portland Cement, wt. % (vol. %)   46 (21.5) 45.6 (21.4) Water, wt. %(vol. %) 16.1 (22.4)   16 (22.3) EPS, wt. % (vol. %)  2.3 (37.3)   3(37.5) Sand, wt. % (vol. %) 35.6 (18.8) 35.4 (18.7)

The following data table numerically depicts the relationship betweenprepuff density and concrete strength at a constant concrete density.

Bead Prepuff Particle Concrete Mean Size, Bulk Density, Density,Compressive μm lb/ft³ lb/ft³ Strength, psi Sample N 650 3.9 85.3 1448Sample O 650 5.2 84.3 1634

The data show that as prepuff particle density in the LWC compositionincreases at constant concrete density, the compressive strength of theLWC increases.

Example 8

The following examples demonstrate the use of expanded slate as anaggregate in combination with the prepuff particles of the presentinvention. Polystyrene in unexpanded bead form was pre-expanded intoprepuff particles having various densities as shown in the table below.The prepuff particles were formulated into LWC compositions, in a 3.5cubic foot drum mixer, containing the components shown in the tablebelow.

Mixed expanded slate/EPS runs Example P Example Q Bead Mean Size, micron0.33 0.4 Prepuff Particle Bulk 5.24 4.5 Density, pcf Weight % Cement19.84% 21.02% EPS 1.80% 1.44% Expanded slate 42.02% 39.07% Water 6.96%7.36% Volume % Cement 9.53% 10.34% EPS 22.71% 21.74% Expanded slate41.91% 39.91% Water 9.95% 10.78% LWC density (pcf) 90.9 93.7 LWCstrength (psi) 1360.0 1800.0

The data show that desirable light weight concrete can be obtained usingthe prepuff of the present invention and expanded slate as aggregate inlight weight concrete compositions.

Example 9

The following examples demonstrate the use of expanded slate as anaggregate used in combination with the prepuff particles of the presentinvention. Polystyrene in unexpanded bead form was pre-expanded intoprepuff particles having various densities as shown in the table below.The prepuff particles were formulated into LWC compositions, in a 3.5cubic foot drum mixer, containing the components shown in the tablebelow.

Example R Example S Example T Example U Example V Example W Bead size(mm) 0.5 0.4 0.4 0.4 0.4 0.4 Prepuff density (lb./ft³) 40 3.4 3.4 3.43.4 3.4 (unexpanded) Weight % Cement 34.4% 35.0% 36.2% 37.3% 35.9% 37.1%Sand 0.0% 23.2% 9.9% 0.0% 15.8% 1.9% EPS 25.0% 1.5% 1.4% 0.6% 1.5% 1.3%Slate 25.9% 26.3% 38.1% 47.1% 32.4% 44.7% Water 14.6% 14.0% 14.5% 14.9%14.4% 14.9% Total 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% water/cement0.43 0.40 0.40 0.40 0.40 0.40 Volume % Cement 15.8% 16.1% 16.1% 18.3%16.1% 16.1% Sand 0.0% 12.1% 5.0% 0.0% 8.0% 1.0% EPS 39.5% 27.3% 24.4%11.9% 26.4% 23.4% Slate 24.7% 25.2% 35.3% 48.0% 30.3% 40.3% Water 20.0%19.2% 19.2% 21.8% 19.2% 19.2% total 100.0% 100.0% 100.0% 100.0% 100.0%100.0% compressive strength (psi) 3813 2536 2718 4246 2549 2516 density(pcf) 89.3 91.1 90.7 98.0 89.7 89.9

Example 10

One-foot square, 4 inch thick concrete forms were made by pouringformulations prepared according to examples X and Y in the table belowinto forms and allowing the formulations to set for 24 hours.

Example X Example Y bead size (mm) 0.4 0.65 Prepuff density (lb./ft³)3.4 4.9 wt % Cement 35.0% 33.1% Sand 23.2% 45.4% EPS 1.5% 2.9% Slate26.3% 0.0% Water 14.0% 13.2 total 100.0% water/cement 0.40 40.0% Volume% Cement 16.1% 16.0% Sand 12.1% 24.7% EPS 27.3% 40.3% Slate 25.2% 0.0%Water 19.2% 19.1% total 100.0% compressive strength (psi) 2536 2109density (pcf) 91.1 90.6

After 7 days, a one-foot square, ½ inch sheet of plywood was fasteneddirectly to the formed concrete. A minimum of one-inch penetration wasrequired for adequate fastening. The results are shown in the tablebelow.

Fastener Example X Example Y 7d coated nails attachment No penetration100% penetration and when slate is attachment encountered removal Easilyremoved Could not be manually removed from the concrete withoutmechanical assistance 2½ inch standard dry wall screw attachment Nopenetration 100% penetration and when slate is attachment. Screw brokeencountered before concrete failed. removal Easily removed Could not bemanually removed from the concrete without mechanical assistance. Screwcould be removed and reinserted with no change in holding power.

The data demonstrates that the present light-weight concretecomposition, without slate, provides superior gripping capability withplywood using standard fasteners compared to traditional expanded slateformulations, while slate containing concrete did not readily acceptfasteners. This represents an improvement over the prior art as the timeconsuming practice of fixing anchors into the concrete to enable thefasteners to grip thereto can be eliminated.

Example 11

One-foot square, 4 inch thick concrete forms were made by pouring theformulations of Examples X and Y into forms and allowing theformulations to set for 24 hours. After 7 days, a one-foot square, ½inch sheet of standard drywall sheet was fastened directly to the formedconcrete using standard 1¾ inch drywall screws. A minimum of one-inchscrew penetration was required for adequate fastening. The results areshown in the table below.

Fastener Example X Example Y 1¾ inch standard dry wall screw attachmentNo penetration 100% penetration and when slate is attachment. Screwcould encountered penetrate through the drywall. removal Easily removed.Could not be manually removed from the concrete without mechanicalassistance. Screw could be removed and reinserted with no change inholding power.

The data demonstrates that the present light-weight concretecomposition, without slate, provides superior gripping capabilitycompared to traditional expanded slate formulations, which did notreadily accept fasteners. This represents an improvement over the priorart as the time consuming practice of fastening nailing studs to theconcrete to allow for attaching the drywall thereto can be eliminated.

Example 12

Two-foot square, 4 inch thick concrete forms were made by pouring theformulations Examples X and Y into a form and allowing the formulationsto set for 24 hours. After 7 days, a three foot long, 2″×4″ stud wasfastened directly to the formed concrete using standard 16d nails. Aminimum of two-inch nail penetration was required for adequatefastening. The results are shown in the table below.

Fastener Example X Example Y 16d nail attachment No penetration 100%penetration and attachment. when slate is encountered removal Easilyremoved. Could not be manually removed from the concrete withoutmechanical assistance.

The data demonstrates that the present light-weight concretecomposition, without slate, provides superior gripping capabilitycompared to traditional expanded slate formulations, which did notreadily accept fasteners. This represents an improvement over the priorart as the expensive and time consuming practice of using TAPCON®(available from Illinois Tool Works Inc., Glenview, Ill.) or similarfasteners, lead anchors, or other methods known in the art to fastenstuds to concrete can be eliminated.

Example 13

Concrete without additional aggregate was made using the ingredientsshown in the table below.

Ex. AA Ex. BB Ex. CC Ex. DD Ex. EE Ex. FF Ex. GG Ex. HH Ex. II StartingBead F271T F271C M97BC F271T F271C M97BC F271T F271C M97BC bead size(mm) 0.4 0.51 0.65 0.4 0.51 0.65 0.4 0.51 0.65 Density (pcf) 1.2 1.3 1.53.4 3.3 3.4 5.7 5.5 4.9 Prepuff size (mm) 1.35 1.56 2.08 0.87 1.26 1.540.75 1.06 1.41 Expansion Factor 48 48 48 18 18 18 12 12 12 wt % Cement33.0 35.8 35.0 33.0 33.0 35.0 33.0 33.0 33.1 Sand 51.5 47.2 50.1 50.350.4 48.9 49.0 49.2 45.3 EPS 0.6 0.8 0.9 1.8 1.7 2.2 3.0 3.0 2.9 Water14.9 16.1 14.0 14.8 14.8 14.0 14.9 14.8 13.2 Volume % Cement 16.0 16.016.0 16.0 16.0 16.0 16.0 16.0 16.0 Sand 28.1 23.7 25.8 27.5 27.5 25.226.8 26.9 24.7 EPS 34.5 38.8 39.1 35.1 35.1 39.8 35.8 35.7 40.2 Water21.4 21.4 19.1 21.4 21.4 19.1 21.4 21.4 19.1 compressive 1750 1650 17201770 2200 1740 1850 2400 2100 strength (psi) density (pcf) 93 87 89 9092 88 89 90 90

The data shows that the average prepuff size required to provide maximumcompressive strength compositions is dependant, to some degree, on theexpansion factor of the prepuff. Focusing on average prepuff size alonedoes not provide a good indicator of maximum potential concretestrength. This point is illustrated by comparing examples BB and FF.Example FF (1.54 mm size) does not provide maximum compressive strengthat an 18× expansion factor, yet it is near the maximum strength that canbe obtained from beads expanded 48×.

Using a combination of prepuff size and expansion factor can provide anindicator for maximum concrete strength. As an example, example AA(prepuff size, 1.35 mm and expansion factor 48) provides 93 pcf concretewith a compressive strength of 1750 psi while a similarly sized prepuff,example II (prepuff size 1.41 mm and expansion factor 12) provides 90pcf concrete with a significantly higher compressive strength of 2100psi. Thus smaller prepuff size and a lower expansion factor can providehigher compressive strength in the present light weight concretecomposition within an optimum range of prepuff particle size.

Example 14

Concrete with expanded slate as an aggregate was made using theingredients shown in the table below.

Ex. JJ Ex. KK Ex. LL Ex. MM Ex. NN Ex. OO Ex. PP Ex. QQ Ex. RR StartingBead F271T F271T F271T F271T F271T F271T F271T F271T F271T bead size(mm) 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 Density (pcf) 3.4 3.4 3.4 3.43.4 3.4 3.4 3.4 3.4 Prepuff size (mm) 0.87 0.87 0.87 0.87 0.87 0.87 0.870.87 0.87 Expansion Factor 18 18 18 18 18 18 18 18 18 wt % Cement 35.933.0 30.5 35.9 33.0 30.6 35.9 33.0 30.6 Sand 0 8.2 15.6 10.6 18.0 24.321.1 27.7 33.2 EPS 1.1 0.8 0.5 1.3 1.0 0.7 1.6 1.2 0.9 Exp. Slate 48.744.8 41.3 37.8 34.8 32.2 27.0 24.9 23.0 Water 14.4 13.2 12.2 14.4 13.212.2 14.4 13.2 12.2 Volume % Cement 16.0 16.0 16.0 16.0 16.0 16.0 16.016.0 16.0 Sand 0 4.5 9.3 5.3 9.8 14.3 10.6 15.1 19.6 EPS 19.9 15.5 10.724.6 20.2 15.7 29.3 24.9 20.4 Exp. Slate 45.0 45.0 45.0 35.0 35.0 35.025.0 25.0 25.0 Water 19.1 19.1 19.1 19.1 19.1 19.1 19.1 19.1 19.1 7 -day 3220 3850 4070 2440 2890 3745 2300 2625 3695 strength (psi) Density(pcf) 92.8 98.5 102.7 90.7 96.8 101.5 88.1 94.5 101.3

The data indicates that while the EPS volume required to maintainapproximately 90 pcf density concrete decreases somewhat linearly as theslate concentration increases; the present light weight concrete'sstrength increases exponentially as the amount of slate in theformulation increases. This relationship highlights the potentiallysignificant impact of including aggregates in the present light weightconcrete formulation and demonstrates the potential for optimizing theamount of EPS and aggregates in the formulation to maximize strength ata desired density. In addition, the cost of various components can alsobe included in such a design and the light weight concrete formulationcan be optimized for both maximum strength and lowest cost.

Example 15

Concrete with unexpanded EPS (1037C) and no additional aggregate wasmade using the ingredients shown in the table below.

Ex. JJ Ex. KK Ex. LL bead size (mm) 0.51 0.51 0.51 Density (pcf) 40 4040 Expansion Factor 1 1 1 wt % Cement 38.7 33.0 28.8 Sand 0 21.6 37.8EPS 43.9 30.4 20.4 Water 17.4 14.9 13.0 Volume % Cement 16.0 16.0 16.0Sand 0 11.8 23.6 EPS 62.6 50.7 38.9 Slate 21.4 21.4 21.4 Water 16.0 16.016.0 compressive 2558 2860 3100 strength (psi) density (pcf) 76 89 100

The data show that unexpanded polystyrene resin beads (˜40 pcf bulkdensity) can provide a light weight concrete composition havingsurprisingly high compressive strength (2500-3200 psi) at low density(76-100 pcf).

Example 16

Prepuff from F271T bead expanded to 1.2 lb/ft³, F271C bead expanded to1.3 lb/ft³ and M97BC bead expanded to 1.5 lb/ft³ were evaluated usingscanning electron microscopy (SEM). The surface and inner cells of eachare shown in FIGS. 20 and 21 (F271T), 22 and 23 (F271C), and 24 and 25(M97BC) respectively.

As shown in FIGS. 25, 27 and 29, the external structure of the prepuffparticles was generally sphereical in shape having a continuous surfaceouter surface or skin. As shown in FIGS. 26, 28 and 30, the internalcellular structure of the prepuff samples resembles a honeycomb-typesturcture.

The size of the prepuff particles was also measured using SEM, theresults are shown in the table below.

T prepuff C prepuff BC prepuff (microns) (1.2 pcf) (1.3 pcf) (1.5 pcf)Outer diameter 1216 1360 1797 Internal cell size 42.7 52.1 55.9 Internalcell wall .42 .34 .24 Cell wall/cell size .0098 .0065 .0043 C prepuff BCprepuff (3.4 pcf) (3.1 pcf) Outer diameter — 1133 1294 Internal cellsize — 38.2 31.3 Internal cell wall — .26 .47 Cell wall/cell size —.0068 0.0150

Taken with all of the data presented above, the data provide anindication that internal cellular structure might affect the strength ofa light weight concrete formulation.

When used in light weight concrete compositions, the prepuff particlescan impact the overall strength of the concrete in two ways. First, thelarger particles, which have a lower density, change the concrete matrixsurrounding the prepuff particle and secondly, the lower density prepuffparticle is less rigid due to the cell structure of the foamed particle.Since the strength of the concrete depends, at least to some extent, onthe strength of the prepuff particles, increased prepuff particlestrength should result in greater light weight concrete strength. Thepotential strength increase can be limited by the extent to which itimpacts the concrete matrix. The data in the present examples suggestthat the original bead particle size can be optimized to provide anoptimally sized prepuff particle (which is controlled by the prepuffdensity), which results in the highest possible lightweight concretestrength.

In other words, within an optimum prepuff particle size and optimumdensity range, the wall thickness of the prepuff will provide sufficientsupport to allow the present light weight concrete composition to havebetter strength than light weight concrete compositions in the priorart.

The data presented herein demonstrate that unlike the presumption andapproach taken in the prior art, expanded EPS particles can dosurprisingly more than act simply as a void space in the concrete. Morespecifically, the structure and character of the prepuff particles usedin the present invention can significantly enhance the strength of theresulting light weight concrete composition.

Example 17

This example demonstrates the use of fasteners with the present lightweight concrete composition and related pull-out strength. Thisevaluation was used to compare the load capacity of a screw directlyinstalled in the present light weight concrete (approximately 90 pcf)with conventional concrete fasteners installed in normal weight andtraditional lightweight concrete.

Fastener pullout testing was performed on three types of concrete:normal weight, 143 pcf (sample MM, 140 pcf normal concrete), lightweightconcrete using expanded slate (123 pcf) (sample NN, 120 pcf LWC), andlightweight concrete with EPS (87 pcf) (sample OO, 90 pcf LWC) made asdescribed above according to the formulations in the following table.

Sample MM Sample NN Sample OO 140 pcf 120 pcf 90 pcf EPS bead size (mm)— — 0.51 density (pcf) — — 3.37 wt % cement 20.2 24.8 32.9 sand 34.636.4 52.7 EPS — — 1.86 ⅜″ pea gravel 37.6 — — ½″ expanded slate — 29.4 —Water 7.7 9.41 12.51 vol % cement 16.0 16 16 sand 30.9 26.5 28.9 EPS — —37 ⅜ “pea gravel 35.0 — — ½ “expanded slate — 39.4 — Water 18.1 18.118.12 comressive 4941 9107 2137 strength (psi) density (pcf) 143 123 87

An apparatus was built that allowed weights to be hung vertically fromeach fastener using gravity to apply a load in line with the axis of thefastener. The 90 pcf LWC had 2½″ standard drywall screws directlyinstalled to approximately 1½″ depth. The 120 pcf LWC had two types offasteners installed into predrilled holes: 2¾″ TAPCON® metal screw-typemasonry fastening anchors (Illinois Tool Works Inc., Glenview, Ill.)installed approximately 2″ deep and standard 2¼″ expanding wedge-clipbolt/nut anchors installed approximately 1¼″ deep. The 140 pcf normalconcrete also had two types of fasteners installed into predrilledholes: 2¾″ TAPCON anchors installed approximately 2″ deep and standard2¼″ expanding wedge-clip bolt/nut anchors installed approximately 1¼″deep. One of the drywall screws in the light weight concrete was backedout and re-installed into the same fastener hole for testing. Also oneof the TAPCON screws was removed and reinstalled to evaluate any loss incapacity. The following tables show the data and loadings for eachanchor/fastener tested.

90 pcf LWC Drywall Screw Stone 1: Screw Exposed Extract and StrengthLength (in) (in) re-install (in) (lb) Screw B 2.5 0.594 1.906 700 @ 30sec.

90 pcf LWC Drywall Screw Stone 2: Screw Exposed Installed StrengthLength (in) (in) (in) (lb) Screw C 2.5 1.031 1.469 >740 > 10 min.

120 pcf LWC TAPCON Screws Stone 3: Screw Exposed Extract and StrengthLength (in) (in) re-install (in) (lb) Screw C 2.75 0.875 1.875 >740 > 10min.

120 pcf LWC Bolt/Sleeve/Nut Stone 4: Anchor Exposed Installed StrengthLength (in) (in) (in) (lb) Anchor D 2.25 0.875 1.375 >740 > 10 min.

140 pcf normal concrete TAPCON Screws Stone 5: Screw Exposed Extract andStrength Length (in) (in) re-install (in) (lb) Screw C 2.75 0.9061.844 >740 > 10 min.

140 pcf normal concrete Bolt/Sleeve/Nut Stone 6: Anchor ExposedInstalled Strength Length (in) (in) (in) (lb) Anchor C 2.25 1.0941.156 >740 > 10 min.

The holding power of the drywall screws in the 90 pcf LWC wassurprisingly high as they did not easily break or tear from theconcrete. The drywall screws were easy to install, only requiring astandard size electric drill. The gripping strength of the drywallscrews in the 90 pcf LWC was such that if the applied drilling torquewas not stopped before the screw head reached the surface of theconcrete, the head of the screw would twist off. All of the fastenersheld the 740 lbs. of load for at least 10 minutes except the backed outand re-inserted drywall screw in the 90 pcf LWC, which held 700 lbs. for30 seconds before tearing loose from the concrete. This drywall screwdid not break at the failure point, but pulled out of the concrete.

Taking the above data as a whole, it has been demonstrated that anoptimum prepuff bead size exists (as a non-limiting example,approximately 450-550 μm resin beads expanded to an expansion factor ofapproximately 10-20 cc/g to a prepuff diameter of approximately 750 to1400 μm for 90 pcf lightweight concrete) to maximize the compressivestrength of the present light weight concrete formulations. Thecompressive strength of the present light weight concrete formulationscan be increased by increasing the present EPS prepuff bead density.Unexpanded polystyrene resin (˜40 pcf bulk density) yields LWC of highcompressive strength (2500-3200 psi) considering the low density (76-100pcf). Aggregates can be used in the present light weight concreteformulations. The present light weight concrete formulations, withoutcourse aggregates, provide a concrete composition, which may be directlyfastened to using standard drills and screws. When the EPS prepuff beadsare expanded to low bulk densities (for example <1 pcf), the beads havea weak internal cellular structure, which creates a weaker foam, and inturn provides a light weight concrete composition having a lowercompressive strength.

Example 18

A lightweight gypsum composition according to the invention was preparedusing SHEETROCK® general purpose joint compound (United States GypsumCompany Corp., Chicago, Ill.), a gypsum based composition reportedlyhaving the following formula:

Limestone or Dolomite or Gypsum (>45%)

Water (>38%)

Mica (<5%)

Vinyl Acetate Polymer or Ethylene Vinyl Acetate Polymer (<5%)

Attapulgite (<5%)

Optionally Talc (<2%)

One part by volume of the joint compound and two parts by volume of theprepuff particles of sample A were blended in a mixer until a smoothuniform composition was obtained.

Lightweight gypsum board samples were prepared in a 12″×4.5″ mold either½″ or ⅝″ thick. Facing paper was used on each side (recycled 50 lb. acidfree paper). One sheet of facing paper was placed in the mold, themixture described above was placed in the mold to fill the volume of themold and a second sheet of facing paper was placed over the light weightgypsum composition. The composition was allowed to set and dry atambient conditions for several days until the weight of the sample didnot change. The resulting board samples had similar physical propertiesto Type X gypsum board.

Control samples were factory produced ½″ standard SHEETROCK gypsum boardand ⅝″ Type X SHEETROCK gypsum board from US Gypsum.

The center of samples (12″×4.5″) were positioned 2.5″ from the nozzle ofa propane torch, which was burned for 90 minutes at 1760° C. The boardsprepared from the present lightweight gypsum composition developed ahoneycomb structure, with minimal crack development. The commercialsheetrock exhibited significant cracks in both the vertical andhorizontal directions. Similar burn through patterns were observed onthe non-flame side of all boards. Similar weight loss was observed byweighing the boards before and after the test (Type X 140 g before, 131g after, 6.4% loss, lightweight gypsum boards according to theinvention, 113 g before, 107 g after, 5.3% loss).

Standard 1¼″ drywall screws were screwed directly into lightweightgypsum boards of the present invention as described above to a depth of½″. The screws could not be manually pulled from the drywall boards.Standard drywall screws screwed directly into the commercial samples to½″ depth could be manually pulled from the board samples.

The examples demonstrate that lightweight gypsum board according to theinvention provides at least similar physical and burn properties tocommercially available gypsum board, while demonstrating the addedbenefit of providing a wall surface that does not require the use ofwall anchors in some instances.

The present invention has been described with reference to specificdetails of particular embodiments thereof. It is not intended that suchdetails be regarded as limitations upon the scope of the inventionexcept insofar as and to the extent that they are included in theaccompanying claims.

1. A lightweight concrete composition comprising from 22 to 90 volume percent of a cementitious mixture, water, and from 10 to 78 volume percent of particles having an average particle diameter of from 0.2 mm to 3 mm, a bulk density of from 0.02 g/cc to 0.48 g/cc, a substantially continuous outer layer, and an aspect ratio of from 1 to 3, wherein the concrete composition is substantially free of air entraining agents; wherein the concrete composition has a density of from 90 to about 130 lb./ft³; and wherein after the lightweight concrete composition when set has a 7-day compressive strength of at least 1700 psi as tested according to ASTM C39.
 2. The lightweight concrete composition according to claim 1, wherein the particles comprise expanded polymer particles having an inner cell wall thickness of at least at least 0.15 μm.
 3. The lightweight concrete composition according to claim 1, wherein the particles comprise expanded polymer particles comprising one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.
 4. The lightweight concrete composition according to claim 1, wherein the particles comprise expanded polymer particles prepared by expanding a polymer bead having an unexpanded average resin particle size of from about 0.2 mm to about 1 mm.
 5. The lightweight concrete composition according to claim 1 as a dispersion wherein the cementitious mixture and water comprises a continuous phase and the particles comprise a dispersed phase of discrete particles in the continuous phase.
 6. The lightweight concrete composition according to claim 5 containing no wetting agents or dispersing agents to stabilize the dispersion.
 7. The lightweight concrete composition according to claim 1, wherein at least some of the particles are arranged in a cubic or hexagonal lattice.
 8. The lightweight concrete composition according to claim 1, wherein the cementitious mixture comprises a hydraulic cement composition.
 9. The lightweight concrete composition according to claim 8, wherein the hydraulic cement comprises one or more materials selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, gypsum compositions, aluminous cements, magnesia cements, silica cements, and slag cements.
 10. The lightweight concrete composition according to claim 1, wherein the cementitious mixture comprises sand, aggregate, plasticizers and/or fibers.
 11. The lightweight concrete composition according to claim 10, wherein the fibers are selected from the group consisting of glass fibers, silicon carbide, aramid fibers, polyester, carbon fibers, composite fibers, fiberglass, combinations thereof, fabric containing said fibers, and fabric containing combinations of said fibers.
 12. The lightweight concrete composition according to claim 10, wherein the aggregate is selected from the group consisting of stone, gravel, expanded slate, pumice, perlite, vermiculite, scoria, diatomite, expanded shale, expanded clay, expanded slag, pelletized aggregate, tuff, macrolite, slate, and combinations thereof.
 13. The lightweight concrete composition according to claim 1, wherein a standard 2½ inch drywall screw, screwed into the formed and set lightweight concrete composition to a depth of 1½ inches, is not removed by applying 500 pounds of force perpendicular to the surface screwed into for one minute.
 14. The lightweight concrete composition according to claim 1 molded and set in the form of a construction article.
 15. The lightweight concrete composition according to claim 1 set in the form of a concrete masonry unit.
 16. The lightweight concrete composition according to claim 1 set in the form of a construction panel.
 17. A concrete composition comprising: from 22 to 90 volume percent of a cementitious mixture containing sand and from 5 to 40 volume percent of a hydraulic cement composition; one or more aggregates selected from the group consisting of stone, gravel, and combinations thereof; water; and from 10 to 78 volume percent of expanded polymer particles formed by expanding polymer beads having an unexpanded average resin particle size of from about 0.2 mm to about 1 mm to an average expanded polymer particle diameter of from 1 mm to 3 mm, a bulk density of from 0.02 g/cc to 0.48 g/cc, a continuous outer surface, and an aspect ratio of from 1 to 3; wherein the concrete composition is substantially free of air entraining agents; wherein after the concrete composition is set and hardened has a density of from 90 to about 130 lb./ft³ and has a 7-day compressive strength of at least 1800 psi as tested according to ASTM C39.
 18. The concrete composition according to claim 17, wherein the expanded polymer particles comprise one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.
 19. The concrete composition according to claim 18, wherein the expanded polymer particles comprise polystyrene.
 20. The concrete composition according to claim 17, wherein the expanded polymer particles having an inner cell wall thickness of at least at least 0.15 μm.
 21. The concrete composition according to claim 17, wherein at least some of the expanded polymer particles are arranged in a cubic or hexagonal lattice.
 22. The concrete composition according to claim 17, wherein the hydraulic cement composition comprises one or more materials selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.
 23. The concrete composition according to claim 17 comprising fibers.
 24. The concrete composition according to claim 23, wherein the fibers are selected from the group consisting of glass fibers, silicon carbide, aramid fibers, polyester, carbon fibers, composite fibers, fiberglass, combinations thereof, fabric containing said fibers, and fabric containing combinations of said fibers.
 25. The concrete composition according to claim 17 comprising aggregate selected from the group consisting of glass, expanded slate, pumice, perlite, vermiculite, scoria, diatomite, expanded shale, expanded clay, expanded slag, pelletized aggregate, tuff, macrolite, slate, and combinations thereof.
 26. A concrete composition comprising: from 22 to 90 volume percent of a cementitious mixture containing: from 1 to 60 volume percent of sand; from 5 to 40 volume percent of a hydraulic cement composition; from 0.5 to 60 volume percent of one or more aggregates selected from the group consisting of stone, gravel, and combinations thereof; and optionally, one or more adjuvants selected from the group consisting of plasticizers, fibers, colorants, water reducers, and superplasticizers; water; and from 10 to 78 volume percent of expanded polystyrene particles formed by expanding polystyrene beads having an unexpanded average resin particle size of from about 0.33 mm to about 1 mm to an average expanded polystyrene particle diameter of from 1 mm to 3 mm, a bulk density of from 0.03 g/cc to 0.48 g/cc, a continuous outer surface, and an aspect ratio of from 1 to 3; wherein the concrete composition is substantially free of air entraining agents; wherein after the concrete composition is set and hardened has a density of from 90 to about 130 lb./ft³ and has a 7-day compressive strength of at least 1800 psi as tested according to ASTM C39.
 27. The concrete composition according to claim 26, wherein the hydraulic cement composition comprises one or more materials selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.
 28. The concrete composition according to claim 26, wherein the polymer particles have an inner cell wall thickness of at least at least 0.15 μm.
 29. The concrete composition according to claim 26, wherein the fibers are selected from the group consisting of glass fibers, silicon carbide, aramid fibers, polyester, carbon fibers, composite fibers, fiberglass, combinations thereof, fabric containing said fibers, and fabric containing combinations of said fibers. 